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If a search engine brings you directly to this page, then
also you may want to look at our
AXLE ASSEMBLY page.
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P1 --- Photo of a Case Bearing showing the Relation of Cone Rotation (2.25 to 1)
relative to one revolution of the Cage.
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P2 --- Photo of Typical Pinion Nuts -- Shown are a flanged and a non-flanged
nut. Both are crimped. The plain nut requires a washer.
To minimize composite runout the nut face contacting the flange
or yoke must be perpendicular to the axis of the nut thread.
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P3 --- Photo of a standard yoke. The Composite Runout Point is
the Center of the Universal and on
the Standard Yoke the location is shown and is obvious.
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P4 --- Photo of a Jeep Flange. There has to be tooling to put the
runout donut spherical center
where the universal center would locate relative to the flange.
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P5 --- Photo of a Ford Flange. To minimize runout for all types of
flanges and yokes the mounting face and pilot diameter must be
perpendicular and concentric with the actual centerline of the spline.
Further the pinion spline axis must be concentric with the axis of
rotation of the pinion.
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P6 --- Photo of the other side of Ford Flange. For all types of
flanges and yokes to minimize runout the face contacting the outer bearing and
the flanged nut or washer seat surface must be perpendicular
to the spline centerline.
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P7 --- Photo of a pinion, pinion shim, inner bearing, collapsible
spacer, and outer bearing. The spline is formed before hardening.
After hardening the bearing
journals are ground relative to the two pinion center holes. After
bearings are installed the concentricity relative to the two center
holes is very good, but the centerline of the spline may not be
concentric or parallel to the axis of rotation of the pinion.
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P8 --- Photo of a portion of the gaging area of a pinion shim
machine. This type of pinion shim gage can provide repeat cycle
repeatability of 0.000,2".
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P9 --- Photo of one type of case shim station. Shows only the case installed.
Very good repeatability. Cast iron carriers should be stress
relieved before gaging. This gage applies very minimal forces on
the case and carrier.
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P10 --- Photo of a bearing gage used with the previous case shim gage.
This type of case shim gages the bearings separate from the
case-carrier gage. Repeatability of this bearing gage is close
to 0.000,1". The bearing is unconstrained and gaged at a force to
provided quick seating of the rollers.
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P11 --- Photo of a Differential Case Assembly with Ring Gear and Side Gears, but
without Case Bearing Cones and Case Shims. This axle would normally have
the shims between the cones and the case, hard to change. This is a
standard unit meaning it is not a limited slip or locker.
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P12 --- Photo of a Cast Iron Carrier with pinion installed
without seal..
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P13 --- Photo of an unassembled Aluminum Rear Axle Carrier.
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P14 --- Photo of an Aluminum Carrier without Gear Side Cap Showing the point on
Seat Surface where gage contacts to measure carrier stretch for
spreader setup for installation of case. Note so long as you stay
within the elastic limit of the material you are stretching you may
hold this stretch as long as desired, years if you want, without
yielding the material.
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P15 --- Photo of an Aluminum Carrier, Cover Plate Side. One way to measure case
preload is to know the change in displacement between the
manufacturing holes for a given force change on the centerline of the
case, spring rate. Before you install the case measure the distance between
the inner sides of said holes, then install the case, tighten cap bolts,
run in case bearings until seated, then determine the change in
distance between holes. Now from the known spring rate of the carrier
you can determine the actual case preload. This method has no validity from
before case insertion to after tubes are pressed in because the shape
of the carrier changes changing the zero reference, and the spring rate
also changes.
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P16 --- Photo of an Aluminum Carrier showing Pinion Side manufacturing hole and
bearing cap identification and orientation marking. The
manufacturing holes are used for locating during machining and some
assembly operations, for stretching carrier for case insertion, and
can be used to measure stretch for case perload determination.
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P17 --- Photo of an an Aluminum Carrier the Gear Side manufacturing hole.
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P18 --- Photo of a sample distribution curve for TIR runout. Measured at
the "composite runout" point. Many axles are
specified at 0.010 max runout, others at 0.007 or 0.008, some
at 0.005 or lower. This curve would be applicable to units with
0.010 limit, not for 0.005 limit parts because the yield would be
only about 60%. Many of the high units are probably due to bad
flanged nuts.
It is a real problem to get flanged nuts with good
perpendicularity of the flange face to the nut thread centerline.
Also nuts are generally crimped.
In one instance, when I was present, production suddenly went to about a
75% reject rate on runout. A couple of boxes of nuts were tried, but no
change. I checked the gage and also did some hand checks of runout which
confirmed the gage was working correctly. I suspected the nuts. At this
time we could
not find any boxes of nuts from a grossly different production batch. Thus,
I decided to try to hand sort nuts. This was done by starting the nut
on a pinion stem and judging if it wobbled too much. This brought the
reject level down to about 40% which was much better. When other nuts
were found the problem went away.
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Note 1:
If a search engine brings you to this site and you do not know
why, then save this page to a file on your computer (under FILE
you would use SaveAs) and after saving, then open the file with
a word processor and search for the words individually that
you used in your search. For example if
the words --- drag torque --- bring up this
site and this page of this site, then you would first search for
drag or torque and look around those locations.
Pick If_search to return to beginning.
.
Copyright
© 2003, 2004, 2005 Gordon A. Roberts All
rights reserved. 050128-1106
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