04 Final Drive. Did it look like this inside?

[Megawatts]

Overhauled this FD a while ago and this is what I found. Have you been inside your's and did you find the same items as pictured (one item imparticular)?
Seen patzx excellent write up but there are differences between the two.
By the way, i'm new here, so go easy. (For the record, sometimes I leave them on and sometimes I take them off).

 

[Bear]

Shouldn't those loose balls be caged?

 

[Megawatts]

Shouldn't those loose balls be caged?

The cage had broken up as shown in picture, the bearing I replaced it with has a thicker cage section. Its the bit to the far right in photo that had me puzzled.

 

[the beer hunter]

The cage had broken up as shown in picture, the bearing I replaced it with has a thicker cage section. Its the bit to the far right in photo that had me puzzled.

It's no puzzle mate, it's buggered!

Maybe a bit of cage broke up the bevel or maybe a bit of bevel broke up the cage?

How many miles had it done?
Was it noisy?
Was it subjected to deep water crossings?
Was all the oil present?

 

[Megawatts]

It's no puzzle mate, it's buggered!

Maybe a bit of cage broke up the bevel or maybe a bit of bevel broke up the cage?

How many miles had it done?
Was it noisy?
Was it subjected to deep water crossings?
Was all the oil present?

Theres nothing wrong with the bevel. The cage was fractured in several places but had stayed in place. No noise, vibration, rumbling had the correct amount of oil in FD. When I gave it a service and was regreasing splined drive shaft noticed a small amount of play on the splined end of pinion (.008"), so stripped it to take a look. Replaced all bearings and seals and done 4000 miles since with no probs. As I say, its that shim washer to the right that I was curious about

 

[the beer hunter]

Theres nothing wrong with the bevel. The cage was fractured in several places but had stayed in place. No noise, vibration, rumbling had the correct amount of oil in FD. When I gave it a service and was regreasing splined drive shaft noticed a small amount of play on the splined end of pinion (.008"), so stripped it to take a look. Replaced all bearings and seals and done 4000 miles since with no probs. As I say, its that shim washer to the right that I was curious about

That pinion looks as if there's a chunk missing?

 

[RickG]

Can't say I remember there being a shim there in my 06 drive. It must set the position of the outer race of the pinion bearing? Congratulations getting it all apart (and back together again)

 

[Magwych]

None shown on the fiche

 

[patzx12]

Hi Mega
How is the rebuild going?
PM me if you have any questions

 

[Megawatts]

Hi Mega
How is the rebuild going?
PM me if you have any questions

Hi patzx
did this rebuild a while ago now and every things running fine. Clearing out the garage last week and came across the bag of bearings seals ect that I renewed and it got me thinking about that shim again that has puzzled me from day one, so I payed me £12 and I thought I would ask you guys.
My first thoughts where that the shim was there to give 360 degrees of support to the needle bearings face due to the fact that the counterbore the bearing sits in breaks through the housing in two places, but I thought nah, surely not. After measuring the old bearing this afternoon it measures 32x15.8, 0.2mm smaller on the width, the shim measured 0.3mm, so may be thats why its there???
The pinion needle bearing was a bit of a pain to get out of the housing, I can see why they put the facility for a rolepin in on later models.
Not gonna loose any sleep over it, done 4k since rebuild, would be just nice to know

 

[Pukmeister]

Why the IR laser thermometer on the machine bed, were you heating the casting in its fixture prior to undoing the bearing retaining ring ?

If so, did it help ??

If things get quiet at work this winter and I get some time in the toolroom I might knock up a fixture and castle nut tool myself for the future in case FD number three needs some internal fettling.

 

[Megawatts]

Why the IR laser thermometer on the machine bed, were you heating the casting in its fixture prior to undoing the bearing retaining ring ?

If so, did it help ??

If things get quiet at work this winter and I get some time in the toolroom I might knock up a fixture and castle nut tool myself for the future in case FD number three needs some internal fettling.

Yeah, I did put some heat on the casing and arouund the pinion nut that has some loctite selant on the thread.
To make the castle nut tool, I just bought a standard 3/4 drive 46mm Draper socket, skimmed the OD of the socket so its a good fit in the housing and then milled the castleations (tough material and hard going on my little mill though only got limited machining facility in my garage but most of what you need is already done for you).

 

[Pukmeister]

I like the idea of machining the socket, why didn't I think of that myself.

Thanks for the idea.

 

[patzx12]

That rollpin on the later FD's is a bitch to get out in one piece, I dont really see the need for it where is the bearing shell going to go.