33 11 523 Renewing Rear Wheel Drive Housing

8/13/2019 33 11 523 Renewing Rear Wheel Drive Housing

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33 11 523Renewing rear wheel drive housing (rear wheel drive removed)

Preparatory work

Draining oil from rear wheel drive

Installing rear wheel drive in retaining fixture

Core activity

(-)Draining oil from rear wheel drivePrecondition

Oil drain plug faces down.

Remove the oil drain plug and drain the oil.

(-)Removing nut from bevel pinionSecure lock (No. 33 2 503)of the retaining fixture so that itcannot turn in the release direction.

Attention

Heating the nut of the bevel-pinion shaft can result indamage to the shaft sealing ring.

Always replace the shaft sealing ring of the bevel pinion ifrepair work necessitates slackening the nut on the bevel-pinion shaft.

Preheat nut (1)and remove it with socket wrench insert(No. 33 1 721).

Technical data

Releasetemperature,pinion nut, rear-wheel drive

100C

Clean the threads on the bevel pinion shaft.

(-)Removing wheel flangeRemove circlip (1).

Mark the position of the wheel flange on the axle for

Page 1 of 18BMW-Motorrad

10/8/2007file://C:\Documents and Settings\Matt\Local Settings\Temp\Temp.xml


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assembly.

Attention

Attempts to install or remove the wheel flange withoutapplying heat can result in damage to the coating of thewheel axle.

Always heat the wheel flange for removal or installation.

If a new wheel axle is installed, the wheel flange has to bereplaced at the same time.

Heat the wheel flange and remove with flange (No. 33 2502), and disc (No. 33 2 506).

Technical data

Releasetemperature,wheel flange,

rear-wheel drive

100...110C

(-)Removing housing cover, rear-wheel driveNote

Replace the shaft sealing ring in the housing if the wheelaxle is removed from the housing of the final drive.

Note that the new shaft sealing ring has to be installed withthe wheel axle in place.

Remove screws (3).

Remove drain plug (2)to prevent the formation of a

vacuum that could make the cover difficult to remove.

Preheat the rear-wheel drive housing, pull the housingcover partly off and remove shims (1).

Technical data

Releasetemperature,housing cover,rear-wheel drive

80C

Remove the housing cover with wheel axle.

(-)Removing threaded ring from bevel pinionRemove threaded ring (1)with pin wrench socket adapter(No. 33 1 711).




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(-)Removing shaft sealing ring from bevel pinionSeat the threaded ring in support (No. 33 2 505).

Use a screwdriver to drive shaft sealing ring (1)out of thethreaded ring.

(-)Removing bevel pinion from final driveHeat the final-drive housing around the bearing.

Technical data

Release/matingtemperature

100C

Install thread adapter (No. 33 2 541)and pull rod (No. 135 251)with impact weight (No. 13 5 253).

Drive out the bevel-pinion shaft, taking care that the ballsof the radial/thrust bearing do not drop out. Use a cloth tocatch the balls if necessary.

(-)Removing shaft sealing ring and bearing forcrown wheel from final drive housing

Remove circlip (1).

Pry out shaft sealing ring (2).




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Install pull rod (No. 13 5 251), impact weight (No. 13 5253)and thrust piece (No. 33 2 521). Check that the thrustpiece is correctly seated.

Heat the final-drive housing around the bearing.

Technical data


100C

Drive out the bearing.

(-)Removing swinging-arm bearing from rear-wheel drive

Firmly clamp retaining fixture (No. 33 2 501)in a vice.

Bolt the rear-wheel drive housing onto the retaining fixture.

Heat the housing around left bearing (1)(as viewed in theforward direction of travel.

Technical data

Release/matingtemperature,swinging-armbearing to final-drive unit

80C

Remove bearing (1)with handle (No. 00 5 500)and drift(No. 23 1 780).

Remove the rear-wheel drive housing from retainingfixture (No. 33 2 501).

Firmly clamp the rear-wheel drive housing in a vice fittedwith plastic jaw protectors.

Remove circlip (2).

Heat the housing around right bearing (3)(as viewed inforward direction of travel).




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Technical data

Release/matingtemperature,swinging-armbearing to final-

drive unit

80C

Drive out bearing (3)with drift (No. 11 6 732).

(-)Removing bearing, Paralever link / rear-wheeldrive

Heat the housing around bearing (1).

Technical data


80C

Remove bearing (1)with spindle and thrust nut (No. 33 2531), support (No. 33 2 532)and washer (No. 33 2 535)(collar toward the outside).

(-)Installing bearing, Paralever link / rear-wheeldrive

Lightly lubricate bearing (1).

Consumables/lubricants

Rubber care product Lubricating andcare of rubbergrommets, O-rings andrubberisedcomponents

83 12 0397 018

Heat the housing around bearing (1).

Technical data


80C




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Install bearing (1)with spindle and thrust nut (No. 33 2531), washer (No. 33 2 534)(mark (B)toward bearing),tapered bushing (No. 33 2 533)(small opening (arrow)toward bearing) and washer (No. 33 2 535)(collar (arrow)toward bearing).

(-)Installing swinging-arm bearing in rear-wheeldrive

Lightly oil bearing (3).


Castrol SAF-XO Transmission oil

Heat the housing around right bearing (3)(as viewed inforward direction of travel).

Technical data


80C

Press in bearing (3)until seated with drift (No. 36 6 600).

Install circlip (2).

Firmly clamp retaining fixture (No. 33 2 501)in a vice.

Bolt the rear-wheel drive housing onto the retaining fixture.

Heat the housing around left bearing (1)(as viewed inforward direction of travel).

Technical data


80C

With the sealing ring toward the inside, install bearing (1)until flush, using spindle and thrust nut (No. 33 2 531),support (No. 33 2 532)and washer (No. 33 2 535), and

adapter disc (arrow)of retaining fixture (No. 33 2 501).(-)Installing bearing of crown wheel in housingcover


Technical data


100C




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Hold the bearing in position and using handle (No. 11 7601)and drift (No. 33 1 571), drive it home quickly andwithout allowing it to tilt.

(-)Removing needle cage of bevel pinionGrip retaining pin (1)with pliers (No. 33 2 561)andremove with pull rod (No. 13 5 251)and impact weight(No. 13 5 253).

NoteInserting a drill bit of suitable diameter into the split pin willprevent the pin from becoming squeezed out of shape andwill facilitate removal.

Install pull rod (No. 13 5 251), impact weight (No. 13 5253)and thrust piece (No. 33 2 523).

Heat the housing around the bearing.

Technical data


100C

Keep tension on the pull rod and make sure that thrustpiece (No. 33 2 523)is in line with the recess in thehousing.

Drive out the bearing.

(-)Installing needle cage of bevel pinionSlip bearing (2)onto drift (No. 11 6 732).

Position bearing (2)square to the bore and drive it fullyhome.

Install retaining pin (1).




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(-)Installing shaft sealing on bevel pinionDrive shaft sealing ring (1)into the threaded ring untilseated with drift (No. 33 1 770).

(-)Preadjusting contact patternRead the number stamped into the housing.

Technical data

Final-drive housing,machining allowance

Stampedinto inside offinal-drivehousing

Read the correction from the crown wheel.

Technical data

Final drive,crown wheel,inscription

Between huband teeth

Use the table to select the correct shim for the bevel




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pinion.

(-)Installing wheel flangeAttention

Attempts to install or remove the wheel flange withoutapplying heat can result in damage to the coating of the

wheel axle.Always heat the wheel flange for removal or installation.

If a new wheel axle is installed, the wheel flange has to bereplaced at the same time.

Heat the wheel flange to the mating temperature, ifnecessary allow the axle to cool.

Technical data

Matingtemperature,wheel flange,rear-wheel drive

100...110C

Matingtemperature,wheel axle,rear-wheel drive

max30C

Using the mark for alignment, mount wheel flange (1)withprimary seal (2)on the axle by hand and without lubricant.

The wheel flange must slip into position easily.

Attention

The rear wheel cannot be installed correctly if the circlip isinstalled wrong way round. In addition, the wheel flangecan move and cause the brakes to overheat.

Make sure that the circlip is correctly seated.

Install circlip (3), making sure that it is correctly seated inthe groove.

The circlip snaps into position with an audible click.




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(-)Installing bevel pinion in rear-wheel driveInstall thread adapter (No. 33 2 541).

Attention

The thickness of the shims between the housing and the

radial/thrust bearing of the bevel pinion determines thetooth contact pattern. A shim of the wrong thickness willlead to an accelerated rate of wear and damage tocomponents.

Always ascertain the thickness of the shim when installinga new gear set or a new housing.

Install spacing washer (3)in housing.

Oil the bearing seat.




Technical data


100C

Position bevel-pinion shaft (2)square to the bore andpush it home quickly and without allowing it to tilt.

Remove thread adapter (No. 33 2 541).

Insert outer bearing race of radial/axial bearing (1)in thehousing.

(-)Installing threaded ring on bevel pinionTo improve the sealing effect, install a threaded ring withlarger groove diameter (a).




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Tightening torques

Housing cover to final drive housing

M8 x 30 Tighten indiagonally

oppositesequence

30Nm(-)Installing nut on bevel pinion

Secure lock (No. 33 2 503)of the retaining fixture so that itcannot turn in the tightening direction.

Tighten nut (1)with socket wrench insert (No. 33 1 721).

Tightening torques

Hex nut, drive bevel gear

Replace nut, M24 x 1.5

Micro-encapsulated

200Nm

(-)Adjusting backlash in rear-wheel driveTurn the crown wheel through several full revolutions inboth directions on the bevel-pinion shaft.

Secure measuring arm (No. 33 2 612)on the wheel axle,

making sure it is centred.Lock the bevel-pinion shaft with counter-holder (No. 33 2591).

Position dial gauge (No. 00 2 510)with dial-gauge holderperpendicular to the mark on the clamping piece in such away that the dial-gauge probe is slightly preloaded.

Zero the dial gauge.

Test

Measure backlash by turning the axle back and forth; donot use the clamping piece to turn the axle.

NoteCheck tooth backlash at three points 120 degrees apart.Make sure there is no oil in the rear-wheel drive for this test.

Technical data

Final drive -tooth backlash

0.1...0.22mm




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Result:Tooth backlash is out of tolerance.

Measure:

Adjusting shims

Removing housing cover, rear-wheel drive


Use a micrometer to measure the thickness of the shimsand make a note of the thickness.

Warning

Risk of injury from the sharp-edged layers of the shims.

Work carefully when removing layers: use a sharp tool andif possible, wear gloves.

If backlash as measured beforehand is excessive, removethe appropriate number of layers.

Technical data

Coatingthickness, shim

4 coatson eachside, eachcoat

0.05mm

If backlash as measured beforehand is insufficient, installthicker shims or fit new shims. Two or more shims can becombined. Remove layers accordingly to obtain thecorrect overall thickness.

Technical data

Coatingthickness, shim

4 coatson eachside, eachcoat

0.05mm

Recheck backlash after correcting the number of shims.

Remove measuring arm (No. 33 2 612), dial gauge (No.00 2 510)and dial-gauge holder.

Remove screws (2).

Pull the housing cover partly off and remove shims (1).Remove the housing cover with wheel axle.




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(-)Checking tooth contact pattern, final driveAttention

Correct tooth backlash is a precondition for the contact-pattern test.

Adjust backlash before testing the contact pattern.

Apply a thin coat of engineer's blue to the flanks of threeteeth on the crown wheel.

Note

The paste for testing the contact pattern is oil-neutral andcan remain on the components; it does not have to bewashed off.


"IRIS"contact-pattern paste Contact-patterntest, final drive

Place the housing cover in position in such a way that theengineer's blue on the tooth flanks is not smudge onto thebevel pinion.

Insert screws (2)and insert the two shims (1). Make surethat the shims are correctly seated: the open noses(arrows)face the recess in the final-drive housing.

Press in the housing cover until flush and tighten screws

(2).

Tightening torques


M8 x 30Tighten indiagonallyopposite




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sequence

30NmTurn the bevel-pinion shaft through several full revolutionsin both directions. The number of revolutions must at leastequal the number of teeth on the pinion. While turning thebevel pinion, use one hand to slow the wheel axle, so as

to obtain a clearly visible contact pattern with theengineer's blue.

Technical data

Final drive, number ofteeth (gear ratio)

31:11,stampedintounderside offinal-drivehousing

Removing housing cover, rear-wheel drive


Test

Result:Fig. 1: Unloaded tooth contact pattern is centred onthe front flank (X) and toward the heel (A) at the rear flank(Y). Fig. 2 shows the tooth contact pattern in operationunder load.

Measure:

Tooth contact pattern is good, setting is correct (idealpattern).

Result:Fig. 3: Tooth contact pattern is offset toward theheel of the tooth (A) on the front flank (X) and toward the toeof the tooth (B) on the rear flank (Y).

Measure:




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The bevel pinion shaft has to be moved in the directionindicated by the arrow (Fig. 4) in order to improve theinstalled position (Fig. 5).

Select a thicker shim for the bevel-pinion shaft.

=> 33 12 570, Adjusting tooth contact pattern (after checkingtooth contact pattern) (Billed as a separate item)

Repeat the test.

Result:Fig. 6: Tooth contact pattern is offset toward the toeof the tooth (B) on the front flank (X) and toward the heel ofthe tooth (A) on the rear flank (Y).

Measure:

The bevel pinion shaft has to be moved in the directionindicated by the arrow (Fig. 7) in order to improve theinstalled position (Fig. 8).

Select a thinner shim for the bevel-pinion shaft.

=> 33 12 570, Adjusting tooth contact pattern (after checkingtooth contact pattern) (Billed as a separate item)

Repeat the test.

(-)Installing housing cover for rear-wheel driveInstall a new O-ring (1), making sure that it is correctlyseated.

Pre-heat the final-drive housing to mating temperature.

Technical data

Matingtemperature,housing cover,rear-wheel drive

80C

Place the housing cover in position and turn the wheelaxle until you feel the splines engage.

Attention

The thickness of the shims between the housing and thehousing cover determines tooth backlash. A shim of thewrong thickness will lead to an accelerated rate of wearand damage to components.

Always ascertain the thickness of the shim when installinga new housing or housing cover, or a new bearing in the




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housing cover.

Insert screws (3)and insert the two shims (1). Make surethat the shims are correctly seated: the open noses(arrows)face the recess in the final-drive housing.

Press in the housing cover until flush and tighten screws(3).

Tightening torques


M8 x 30 Tighten indiagonallyoppositesequence

30NmInstall oil drain plug (2).

Tightening torques

Oil filler plug in final drive housing

with O-ring 11.2 x 1.8, M12x 1

20Nm

(-)Installing nut on bevel pinionSecure lock (No. 33 2 503)of the retaining fixture so that itcannot turn in the tightening direction.

Tighten nut (1)with socket wrench insert (No. 33 1 721).

Tightening torques

Hex nut, drive bevel gear

Replace nut, M24 x 1.5

Micro-encapsulated

200Nm

(-)Installing shaft sealing ring of wheel axle inhousing

Oil sealing lip of shaft sealing ring (1)and its friction face.



Drive in shaft sealing ring (1)until seated with drift (No. 33




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1 892).

Install circlip (2), making sure that it is correctly seated.

Install cover (3).

(-)Replacing flexible gaiterReplace flexible gaiter (1)with plastic inserts (2)and (3).

Finishing work

Filling rear-wheel drive with oil (initial filling)
