T-EPE-0004-E Assembly Instructions Unit Pack

Before the beginning of the dismantling:

Neither high pressure or steam water nor aggressive chemicals may be used for this.

Continuous numbering of the individual propshaft bearing faces on the relevant yokes with the numbers 1 to 8 as per the sketch

The circlips serve to maintain the fixing and axial movement of the UPs. They are adjusted for thickness and may on no account be swop over.

Therefore the marking of each individual circlip is important immediately after its dismantling. For the marking strips of adhesive tape may be used, which may be marked and attached to the circlips.

The circlips should receive the same number as the relevant bearing. vIf the circlips are mixed up this leads to high out-of-balance values. The Joint adjustment has to be inspected, see also Point 5.3.6

Insert wisdom here.

Insert wisdom here.

Insert wisdom here.

Place joint on work bench, put mandrel (see Fig. 2) into the lug hole and make the bearing cup “sit” by use of a heavy blow with a hammer. For mandrel dimensions see Table 1.

Remove circlip with dismantling pliers. Turn joint and remove the remaining circlips as described.

Force the bearing cup out of the tube yoke with a press.

Additionally, support the flange yoke and force the tube yoke downwards, so that the bearing cup comes out at the top of the tube yoke.

Then turn the propshaft 180° and force out the other bearing cup. In doing this attention should be paid that the tube yoke does not come into contact with the bearing cross.

Alternative

In cases where no press is available the bearing cups may also be driven out by means of hammer blows (soft metal).

Oiling of the bearing cups eases the driving out. Use a vice as support.

The bearing cups should be dismantled with the fixture shown on the right (clamping sleeve) while fixed in a vice.

Ø A = Bearing cup-Ø

The bearing cups should be taken out of the tube yoke.

In addition the bearing cups should be held in the vice and driven out by light blows to the yoke ears.

The flange yoke with the fitted journal cross should be removed.

The bearing cups should be removed from the flange yoke in the same manner . For this the bearing cups should be held with the fixture clamping sleeve in the vice and pulled out through light hammer blows on the flange yoke ears.

Take the journal cross out of the flange yoke ear. The fixed joint is now disassembled.

The dismantling of the slip joint takes place in the same manner as the dismantling of the fixed joint.

Fit bearing cup and press in until it is visible on the inner side of the yoke ear (see arrow).

The journal cross should be laid in the flange yoke.

The assembly pressure to be used to press home the bearing cup should be taken from table1.

Insert circlip.

Here it is most important to retain the correct order of circlips to the lug holes.

Press the bearing cup with the journal cross and the opposing bearing cup against the circlip.

The bearing cups are fitted with plastic thrust washers.

So that the thrust washers are not crushed in the assembly of journal crosses into yoke ears, the maximum pressure force values (according to table 1) may not be exceeded.

Insert the 2nd circlip. So that the ring fits exactly into the groove.

We recommend to give a hammer blow onto a mandrel that is laid onto the circlip (mandrel dimensions see table 1).

The journal cross with the already fitted flange yoke should be inserted into the ears of the tube yoke.

The remaining process is as per the assembly of the flange yoke journal cross.

“Ease” joints (through hammer blows on the yoke ears).

The unit pack assembly and the grease cushion should be taken out of the packaging.

The four bearing cups should be removed from the journal cross. The yokes which are to be assembled should be cleaned.

The grease reservoirs in the journal crosses should be filled from the grease cushions provided.

The assembly of the UPs can then be carried out as under Item 5.3 re-greasable UPs.