1980 SKODA 120 LS differential

4.3-4.4
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{.3-4.4
6. Remo
b) Crownwl Tools:
Settin
not le
1. Install
one of the
Glave Cylir
that the p
pendicular
2. Lock
between tl"
cover. 3. Using
back and
clearance I
teeth. This gauge, anc
wheel(see legible the
O.18mm bi
4. lnsuffi
wheel is tc
increase tl
from the nc
the equiva
This will p
increase th
Excess c
thickness
Selector Si
To worl
shims to n
(a) Bac
(b) Act
Refitting C Assembly
29. Instc
ond the rel it with nutr
-looded brc
To
(a) O.3i
(b) o.2r
lf
the shims
connot be set up exoctly to the
colculoted thickness, determine o thickness
which would result
in o prelood
due to on
overoll increose of 0.03 to 0.07 mnr of the di-
rnension of the shims.
27. Ploce the topered roller beoring on the
respective bore, bolt the other MP 5-107
iig on
the housing ond rotote
the centre bolt to press
the beoring into the housing os for os it will go.
Remove the iig, fit the shrunk-on
ring on the
stor pinion,
and lock the ring in position
using
o circlip. Lubricote the beoring with oil, f it the
respective shims on the beoring ond the gosket
on the cover, ond bolt down the cover.
Turn over the housing ond press-in
the other
beoring in the some monner (the press-fitting
iig is olreody in
position),
instoll the preporred
shims, ond bolt down the cover with its gosket.
28. Meosure how deep is tlre drive shoft
beoring below the level of tlre housing
surfoce
ond compensote the difference
with shims up
to o moximum protrrrsion
of 0. I mm -F0.05
rnnr.
Fig.4.3/4 -
Press-f itting of Differentiol Toperecl
Rollr:r Beorings
Using MP 5-107 Jig
Shims 0.1 nrm to 0.2 mm thick ore ovoiloble.
Fit the gosket
ond the ossembled cover on the
housing ond fosten it with nuts ond spring
woshers (for the cover refer
to Chopter 4.5).
Swing down the beoring
with the speedo-
meter drive geors
in the cover into engoge-
nrerrt with the pinion
drive geor
ond lock the
beoring in position
by tightening the nut of the
beoring clip.
Adjusting crownwheel Bearing
Alternative Method a) Crown Wheel Bearing Preload.
Tools Dial Test Gauge and Stand
MPs -
1OG lever Setting:
Preload O.Ob -
O.10 mm
1. Before assembling Transmission casing
remove outer crown wheel bearing races. Leave
the bearings on the
differential housing.
2. Assemble transmission. DO NOT carry out
operation 17
above.
3. Fit the outer races into casing pressing
into
place using coned cover. Do not forget to fit
gaskets. On the Selector Shaft side (side
B) of the
casing fit
approximately O.60 mm of shims
between the coned cover and outer races. Ensure
there is
backlash between crownwheel and
pinion, increase the
shim thickness if required.
4. Fit Dial test gauge
so that pointer
rests on
the differential as shown in fig. 4.3/1A.
5. Lift Crownwheel assembly to determine
clearance between bearings (a).
. . lf this exceeds
O.2O mm decrease the clearance to between O.O1
and 0.20 mm by f itting
shims to Non-selector side
of casing. (b)
. . . When the clearance is between
0.01 and0.20 mm take
a reading. Addtothis0.OS
to 0.10 mm. Make a shim pack
to this thickness
and fit to non-selector side (side
A) of transmission
casing. Check some
backlash still exists between
the Crownwheel and pinion.
Example 1st Dial reading 0.3O mm
0.20 mm
Shim fitted
on non-selector side.
2nd Dial reading 0.07mm
Shim pack
required between
0.07 +O.O5 =O.12mm
and0.O7mm *O.1Omm
= 0.17 mm
Shim sizes available.
0.08, O.14, O.2O and O.SOmm
Shim size selected O.14mm. This
will give
O.07mm preload
tension to crownwheel
beari ngs.
The Crownwheel should now
turn freely with
little drag. Fis.
4.3/1A
82

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4.9-4.
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Fig. I
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3. To evoluote
the doto
obtoined from
the diol
indicotor reoding ond the
doto of the geor
set,
odopt the following procedure:
The setting distonce of the gouge -
60.00 mm
- is morked on the gouge
orm; the reoding
of
the diol indicotor
hos shown
o deviotion
of e. g.
plus 66 divisions, i. e. 0.66 millimetres (plus
meons thot the tip
of the gouge is pushed
in-
word from the set zero position
ond the in-
dicotor reoding is higher;
o reverse deviotion -
minus reoding -
connot procticolly
occur). By
subtrocting this deviotion from the meosure on
the gouge, the octuol distonce between the
pinion ground foce ond the geor
cross oxis will
be obtoined,
i. e. 60.00 mm minus 0.66 mm :
59.34 mm.
The meosure on the crown
wheel indicoting
the ossembly
distonce of the pinion
is, foi
exomple, 59.60. Accordingly,
the pinion
must be
moved slightly
out of the housing
0.26 mm, i.
e.,
by the difference
of the two
meosurings (59.60
minus 59.34:0.26 mm).
4. Prepore
odiusting
sirims 0.30 mm thick to
be inserted
under the flonge
of the pinion
beor-
ing on further
ossembly of the housing.
Shims 0.14, O.2, 0.3, ond 0.5 mm thick ore
ovoiloble. lf the required
occurote outword shift-
ing of the pinion
connot be ochieved
with shims
of ony of the specif
ied thickness, combine them
to obtoin
the next higher
volue.
Note: The thickness of shims required
for the od-
iustment of the
pinion
con be olso
colculoted
in the following
woy:
o) Set the diol indicotor
of the Mp 5-103 gouge
os in porogroph
1of the preceding
texi i.6.,
with the gouge
odiusted on the meosuring
contoct, the reoding
of the diol indicoto-r
will be 1.00 mm.
b) .Swing the
tip of the diol
indicotor
ogoinst
the pinion ground foce ond push
the
iinion
by meons
of the Mp 5-102
beorinq
retoiner
into the housing
till the diol
indicitor reods
1.00 mm. pointer
ofter pushing
the pinion
into the
housing is the meosure (thickness)
of the
shims.
4.9 DIFFERENTIAL
Assembly 1. Instoll the sun geor (plonet)
without the
friction wosher, the two stor pinions
(sotellites),
ond the pilot pin
for the stor pinions
into the
left-hond holf of the differentiol cose (with
the
flonge for the crown wheel). The originol
dif-
ferentiol pinion
shoft pressed into the cose
must be reploced tempororily by the pilot
pin
to focilitote hondling. 2. Push the sun geor
from outside into
en-
gogement with the stor pinion
teeth ond
use
o depth gouge
to meosure the dimension by
which it protrudes
from the housing. Then, pro-
ceeding from inside, push
the sun geor
into the
obutment surfoce of the differentiol cose ond
meosure ogoin
by how
much lt protrudes
from
the housing. The difference of both meosure-
ments determines the gop
for the sliding ring.
The rings ore supplied
in thlcknesses of 1.8,
1.9,
2, 2.1,2.2, ond 2.3
mm. Select the ring whlch is
0.1 mm thinner thon
the colculoted dimension
of the gop.
Fig. 4.9/1- Sectionol View of Differentiol
The orrow points to the mork indicoting the
side for pressing-on
the differentiol pinion
shoft. Any symbol con be used (o
figure, o let-
ter) but it must be identicol for both ports
of
the differentiol. lt olso indicotes the
correct
relotive position of the two differentiol ports.
c)
d) Push,
the pin-ion further into the housing
{while w.otching
the deflection
of the poin-.
ter) until the ossembly
meosuring
is ob-
toined (the 59.60 meosure
on th; crown
wheel) , i.
e., by the dif ference
of this
meosuring from 60.00
mm -
in our exomple
60.00 minus 59.60:0.40
mm.
Without chonging the position
of the
diol
Indicotor, push
the pinion into the housing
gs for os
it
will go -
the difference
of th6
d.iol reoding
from the previous
0.40 mm is
the thickness
of the required
shims (0.26
mm). Or, without chonging
the position
of
the diol indicotor on tfrJ pinion,
trin tf,e
scole to zero (0).
The
deilection
of the
90 Fig-