Bln-10169 Phased Out i Jan-1999 Rev b

BLN-10169 IHT M15IHT M15 Differential Replacement

Copyright 1998, Sauer-Danfoss Company. All rights reserved. Contents subject to change. Printed in U.S.A.

PURPOSE:This bulletin is intended to give instructions for replacement of a differential gear set and/or a ringgear and pinion gear shaft assembly in the IHT M15.

Transmission must be removed from the vehicle, oil drained, and the exterior cleaned before per-forming this service procedure. After disassembly, thoroughly clean all gasket surfaces. Replace allgaskets and seal included with service kit(s).Refer to figure one for component identification numbers used throughout this procedure.

PARTS REQUIRED:

The instructions in this bulletin are for any of the following kits. Use table below to determine whichkit are necessary for your repair.

tiKlaitnereffiD tiKnoiniPdnagniR noiniPdnagniR/wtiKlaitnereffiDnoiniPdnaHthgiR 9720154 0820154 2820154

noiniPdnaHtfeL 9720154 1820154 3820154

Fig. 1 Drain Plug Location Fig. 2 Filter Location

Filter

Integrated Hydrostatic Transaxle M15The components of each kit are listed below and on the next page. Refer to figures 3 & 4.4510279 Differential Kit, IHT 1 ea.Consisting of:

BLN-10169 Instructions 1 ea.5000021 Seal-Lip, 25.0 SFT x 47.0 OD x 7.0 mm 1 ea.9700929 Filter, IHT 1 ea.3104231 Differential Assembly with Bearings 1 ea. Consisting of:

3104232 Differential Assembly without Ring Gear 1 ea.5000014 Bearing Cone 2 ea.5000015 Bearing Cup 2 ea.

3103624 Gasket - Front Cover, IHT 1 ea.3103631 Gasket - Axle Housing, IHT 2 ea.5000412 Screw - Hex FLG M8 x 30 - 10.9 6 ea.3103991 Shim 2 ea.3103993 Shim 4 ea.

4510280 Ring and Pinion Kit, IHT (RH Pinion) 1 ea.Consisting of:

BLN-10169 Instructions 1 ea.5000518 Nut-Hex Lock M20 DIN 985-6 1 ea.5000528 Washer - .797 X 1.281 Special Hardened 1 ea.3104233 Rear Gear Assembly 1 ea. Consisting of:

3104234 Ring and Pinion Assembly 1 ea.5000227 Bearing Ball 1 ea.

5000526 Hex Screw, M10 X 1.5 X 16 10 ea.5000399 Screw-Soc Hd Torx, M8 X 25 - 10.9 SPCL 6 ea.3103620 Gasket - Housing, IHT 1 ea.

4510281 Ring and Pinion Kit, IHT (LH Pinion)Consisting of:

BLN-10169 Instructions 1 ea.5000518 Nut-Hex Lock M20 DIN 985-6 1 ea.5000528 Washer - .797 X 1.281 Special Hardened 1 ea.3104235 Rear Gear Assembly 1 ea. Consisting of:

3104236 Ring and Pinion Assembly 1 ea.5000227 Bearing Ball 1 ea.

5000526 Hex Screw, M10 X 1.5 X 16 10 ea.5000399 Screw-Soc Hd Torx, M8 X 25 - 10.9 SPCL 6 ea.3103620 Gasket - Housing, IHT 1 ea.

Integrated Hydrostatic Transaxle M15

COMPONENT IDENTIFICATION:

1. Lock Nut2. Washer3. Small Pinion Bearing4. Spacer5. Drive Gear6. Bearing Retainer7. Bearing Retainer Screw8. Pinion Gear Shaft and Bearing Assembly9. Hydraulic Housing Gasket

Fig. 3 IHT Pinion Gear Assembly

4510282 Differential w/ Ring and Pinion Kit, IHT (Right Hand)Consisting of:

4510279 Differential Kit, IHT 1 ea.4510280 Ring and Pinion Kit, IHT 1 ea.

4510283 Differential w/ Ring and Pinion Kit, IHT (Left Hand)Consisting of:

4510279 Differential Kit, IHT 1 ea.4510281 Ring and Pinion Kit, IHT 1 ea.


10. Axle11. Auxiliary Mounting Pad12. Clutch / Brake13. Front Cover14. Snap Ring15. PTO Shaft Seal16. PTO Shaft Bearing17. Differential Bearing Clamp18. Differential19. Differential Bearing Carrier20. Shim21. Ring Gear22. Gear Housing23. Left Side Bearing Cup24. Right Side Bearing Cup25. O-Ring26. Front Cover Gasket27. Axle Gasket28. Ring Gear Screw

Fig. 4 IHT Gear Housing Assembly

Integrated Hydrostatic Transaxle M15PROCEDURE:

Note: Refer to fig's 3 and 4 for assemblysequence numbers, (shown inparenthesis) used throughout thisprocedure.

1. If an auxiliary pump (not shown) is in-stalled on the auxiliary mounting pad,remove it.

2. Remove the auxiliary mounting pad (11)(or cover) from the front cover. (Fig.5)

3. Using a 5mm internal hex wrench, re-move the 6 screws securing the clutch /brake assembly (12) to the front cover.(Fig.6)

4. Using a 15mm wrench, remove the 10front cover bolts. (Fig. 7)

Fig. 6 Removing the clutch / brake screws.

Fig. 7 Removing the front cover bolts.

Fig. 5 Removing the auxiliary mounting padcover.


5. Remove the front cover (13) from thetransmission housing. (Fig. 8)

6. Flush the case to remove any loosedebris.

7. Remove the snap ring (14) that retains thePTO shaft seal. (Fig. 9)

8. Remove the PTO shaft seal (15) andbearing (16) by pressing from inside thefront cover. Discard seal. (Fig. 10)

Fig. 9 Removing the PTO shaft seal snap ring.

Fig. 8 Removing the front cover.

Fig. 10 Removing the PTO shaft seal andbearing.


Fig. 11 Assessing ring gear and the piniongear.

Fig. 12 Removing bolts from housing.

Fig. 13 Removing transmission housing fromthe hydraulic housing.

9. At this point carefully assess the conditionof the ring gear (21) and the pinion gear (8).If no damage is detected skip steps 10 -14, and steps 33 - 38 and continue withreplacing the differential. If damage isdetected, order ring and pinion gearreplacement kit from Sauer-Sundstrand.*Two kits exist for right and left hand gearsets. To determine which one to use, lookat the pinion gear. If the teeth curve to theright, order kit 4510280. If they curve tothe left , order kit 4510281. If you are notsure which kit to order contact your Sauer-Sundstrand representative. (Fig. 11)

10. Using a 17mm wrench remove the thir-teen bolts that connect the hydraulichousing to the gear housing (22).(Fig. 12)

11. Using a soft mallet strike the gear housingto remove the hydraulic housing. (Fig. 13)

* Kit 4510282 and 4510283 already include ring andpinion gears.


Fig. 14 Removing the lock nut.

Fig. 15 Removing the washer, bearing,spacer, and drive gear.

Fig. 16 Removing the bearing retainer.

12. Using a 30mm wrench remove the locknut (1) from the pinion gear shaft (8).The rotation of the axles must be blockedat both ends before nut can be loosened.(Fig. 14)

13. Remove the washer (2), small bearing(3), spacer (4), and drive gear (5) fromthe pinion gear shaft. (Fig. 15)

14. Using a 5mm internal hex wrench,remove the six screws that attach thebearing retainer (6). Remove pinion gearshaft and bearing assembly (8). (Fig. 16)

Block axles fromrotating


17. Using a 10mm wrench, remove the sixdifferential bearing carrier screws.Discard existing screws. (Fig. 19)

Fig. 18 Removing the differentialbearing clamp.

Fig. 19 Removing the differential bearingcarrier screws.

16. Using a 16mm wrench, remove the twodifferential bearing clamp bolts. Removethe differential bearing clamp (17).(Fig. 18)

Fig. 17 Removing the axles.

15. Using a 16mm wrench, remove the sevenaxle bolts from each axle. Remove theaxles (10). (Fig. 17)


19. Using a 15mm wrench, remove six of theten ring gear screws from the differential,leaving four screws evenly spaced aroundthe circumference. Loosen the remainingfour until they stand about 12mm [1/2 in]above the surface of the differential.

Fig. 20 Removing the differential.

20. Using a soft mallet, tap the four screwsapplying even pressure to drive the ringgear off of the differential. If ring gear isdamaged, discard. (Fig. 21)

21. With the ring gear free, remove theremaining four screws. Remove the ringgear. Fig. 21 Removing the ring gear.

18. Remove the differential (18) and differen-tial bearing carrier (19). If shims (20)were used in assembly, retain for reas-sembly. (Fig. 20)

22. Install the ring gear to the new differen-tial.

23. Install all ten screws and tighten themevenly working your way around thedifferential in a crisscross pattern. Thisoperation presses the ring gear onto thenew differential.

24. Torque the ring gear screws to 75 Nm [55 lbfft] again using a crisscross pat-tern. (Fig. 22)

Fig. 22 Installing the ring gear.


25. Install left hand side bearing cup (23) andany existing shims to the differentialbearing carrier. (Fig. 23)

26. Install the right hand side bearing cup (24)and any existing shims. (Fig. 24)

Fig. 23 Installing the left side bearing cup.

Fig. 24 Installing the right side bearing cup.

Add shims only as required. (See step 30)

Add shims only as required. (See step 30)

27. While holding the differential in place,install the bearing carrier and differentialclamp. (Fig. 25)

Fig. 25 Installing the differential.


28. Torque the differential bearing clamp boltsto 98 Nm [73 lbfft]. (Fig. 26)

29. Install new bearing carrier screwsincluded with kit. Torque the bearingcarrier screws to 43 Nm [32 lbfft].(Fig. 27)

Fig. 26 Installing the differential bearingclamp.

Fig. 27 Installing the differential bearing carrier.30. Using a dial indicator on the ring gear,

check the backlash by rocking the differen-tial back and forth without turning thepinion gear. Backlash should be .254mm+/- .101 [.010 in +/- .004]. Extra shims(.005 in and .008 in) are included with thekit and may be used as required to setbacklash within desired range. To in-crease backlash, shim between the differ-ential clamp and the right hand sidebearing cup. To decrease backlash, shimbetween the differential bearing carrierand the left hand side bearing cup. Aftershimming, reinstall the differential persteps 25 through 29. Recheck backlashand repeat shimming as necessary.(Fig. 28) Fig. 28 Checking the backlash.


Fig. 29 Installing the axles.

Fig. 30 Installing pinion gear shaft andbearing assembly.

Fig. 31 Installing bearing retainer.

31. Install the axles using new gaskets (27).(Fig. 29)

32. Install the axle bolts. Torque to 98 Nm[73 lbfft].

33. Install new pinion gear shaft and bearingassembly to the gear housing. (Fig. 30)

34. Install the six new screws securing thebearing retainer. Torque to 38 Nm[28 lbf.ft] (Fig. 31)


Fig. 32 Installing drive gear, spacer, bearing,and washer.

Fig. 33 Installing lock nut with Loctite.

Fig. 34 Aligning hydraulic housing totransmission housing.

35. Install drive gear, spacer, bearing, andreplacement washer. (Fig. 32)

36. Apply Loctite #7070 cleaner or equiva-lent to threads of the pinion shaft and nut.The threads must completely dry beforeassembly. Apply Loctite #271 or equiva-lent thread locking compound to a mini-mum of 4 thread widths for 360 degreesof the nut and shaft. Hand tighten locknut so the large bearing surface of the nutfaces the pinion end of the shaft, thentorque to 244 Nm [180 +/- 10 lbfft].(Fig. 33)

Note: Allow 2 hours for compound to curebefore operating unit.

37. With new gasket in place and all gearsand shafts properly aligned, mount gearhousing to the hydraulic housing.(Fig. 34)


Apply Loctite 515flange sealant or

equivalent to shadedarea.

Fig. 37 Installing the front cover bolts.

Fig. 36 Apply flange sealant.

Fig. 35 Installing transmission housing to thehydraulic housing.

39. Install front cover gasket (26). Treat thecircular area around the clutch / brakeassembly with Loctite 515 flange sealantor equivalent. Use a small bead on bothsides of the gasket. (Fig. 36)

40. Install front cover. Start the front coverbolts, do not torque. (Fig. 37)

38. Install the thirteen bolts that secure thegear housing to the hydraulic housing.Torque to 54 Nm [40 lbf.ft]. (Fig. 35)


Fig. 38 Installing clutch / brake screws.

Fig. 40 Installing PTO shaft seal.

Fig. 39 Installing PTO shaft bearing.

41. Install the 6 screws securing the clutch /brake assembly to the front cover.Torque to 11 Nm [8 lbfft]. (Fig. 38)

42. Install the PTO shaft bearing. (Fig. 39)

43. Using an installation cone / bullet to pro-tect it, install the PTO shaft seal. Pressinto place evenly. Ensure that seal ispressed deep enough to expose the snapring groove. (Fig. 40)


Fig. 41 Installing snap ring.

Fig. 42 Torquing the front cover bolts.

Fig. 43 Installing the auxiliary pad o-ring.

O-Ring

44. Install the snap ring which retains thePTO shaft seal. (Fig. 41)

45. Torque front cover bolts to 54 Nm[40 lbfft] using a crisscross pattern.(Fig. 42)

46. Install the auxiliary pad (or cover) usingnew o-ring. Ensure that the o-ring isseated properly in the groove in the frontcover. (Fig. 43)


Page 18

SAUER-DANFOSS COMPANY2800 East 13th Street Ames, IA 50010 USAPhone: +1-515-239-6000 Fax: +1-515-239-6618

BLN-10169 Revision B JAN. 1999

Fig. 44 Installing the auxiliary pad cover.

Fig. 45 Filter location.

Filter

47 Install the auxiliary pad (or cover) andbolts. Torque to 54Nm [40 lbfft].(Fig. 44)

48. If used, Install the auxiliary pump (notshown).

49. Replace filter after assembly and againafter 50 hour break-in period. (Fig. 45)

Bln-10169 Phased Out i Jan-1999 Rev b

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