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Service Manual Kessler transfer box

GMK 5100
Single speed Transmission with flanged-on Axle differential

AD41-W2500

JCL August 2000

 Index
Axle differential

1. Assembly of the axle differential 4.20.3

2. Adjustment of the gear meshing 4.21.2

3. Assembly and bearing adjustment of the drive gearwheel 4.32.1

4. Assembly and bearing adjustment of the drive pinion with side gearwheel 4.9.4

5. Differential installation 4.20.4

6. Assembly of the differential lock 4.20.5

7. Assembly of the axle disconnect 4.32.2

8. Assembly of the through drive shaft 4.32.3

Transmission

9. Pre-assembly of the input shaft 2502

10. Pre-assembly of the intermediate shaft 2503

11. Pre-assembly of the output shaft with differential 2504

12. Power divider drawings 2505

13. Pre-assembly of the gear housing 4.32.4

14. Gear housing sub assembly drawing 4.32.5

15. Assembly of the intermediate shaft 2508

16. Pre-assembly of transfer case 4.32.6

17. Drawing of pre-assembly of transfer case 4.32.7

18. Assembly of the differential lock 4.32.8

19. Assembly of the oil pump 4.32.9

20. Final assembly of the drive assembly.

Supplements:

21. Adjustment of the gearmeshing of the Gleason gears 4.0.1

22. Service tools 3.6.2/3

23. Bolt torques 3.3

24. Flange nut torques 3.5

25. Locking flange nut instruction 4.0.2

 Service Manual 4.20.3

Assembly of the Differential

Before assembly all of the bevel gears and the thrust rings should be well oiled .

1. Install the bearing bushings into the

differential housings . Place one differential
side gear with the side gear thrust washer in
the differential case .

2. Install the spider with differential gears and

differential pinion thrust washers in the
differential case .

3. Install the other differential side gear and side

gear thrust washer .

4. Install the other half of the differential case

over the assembly and observe the alignment
marks , tighten the differential case bolts .
Secure with Loctite 262 .

5. Check that all differential pinions can rotate

easily .

6. Coat the contact surface of the ring gear with

Loctite 270 and install the ring gear on the
differential case by tapping lightly on the
circumference . Tighten the ring gear bolts .
Secure with Loctite 262 .

7. Heat the two taper roller bearings to about 100

° C and install them by using a sleeve .
 Service Manual 4.21.2

Adjustment of gear meshing

To obtain the proper tooth flank contact, adjust the axial
position of the drive pinion with the thickness of the
adjustment disk . The necessary thickness of the
adjustment disk can be obtained by measurement.
(S theor. = 3 mm ) .
1
A = Desired value for correct pinion support . This
dimension is written on the end face of the pinion in
1/100 mm . It indicates the deviation from the theoretical
distance ( setpoint dimension ) . 5
B = Measured width of the taper roller bearing .
(B theor. = 40 mm ) .
1. Calculation example to establish the thickness S of
the adjustment disk :

Measured Difference

B 37,95 + 0,05

A ,10 - 0,1 2
4
total - 0,05 7

Necessary thickness of the adjustment disk:

S = 3 - 0,05 = 2,95 mm

2. Heat the taper roller bearing ( 5 ) ( drive pinion side ) to

about 100 ° C and install it on the drive pinion shaft.
(After cooling, drive on for contact ) . 6
3. Fit the disk ( 6 ) and outer ring of the taper roller bearing
into the differential carrier ( 3 ) . 3

4. Install the drop gear housing .

5. Press the taper roller bearing ( 4 ) into the

drop gear housing. Install the drive pinion.

6. Tighten the safety nut ( 2 ) until there is a

small bearing roll resistance .

7. Place the differential with the outer rings

of the taper roller bearings on the
differential carrier and adjust the teeth
side play ( see assembly of drive S
assembly ) . If the gear meshing is not
correct, modify the thickness S of the B
adjustment disk .

8. Detach differential, drive pinion and drop gear housing .

 Service Manual 4.32.1

Assembly and bearing adjustment of the drive gear

1. Install the deep groove ball bearing (
8 ) into the cover ( 9 ) and install the
circlip ( 21 ) , install the radial seal ring
( 10 ) with Loctite 572 applied into the
cover, fill the radial seal ring with
bearing grease . Place the cardan
screws ( 11 ) into the drive flange (12)
and press the drive flange into the
deep groove ball bearing . Install the
circlip ( 13 ) into the slot of the drive
flange . Place O - ring ( 14 ) into the
slot of the cover , install the cover onto
the drop gear housing ( 7 ) and bolt it .
2. Heat the two taper roller bearings ( 15
+ 16 ) to about 100 ° C and install
them onto the drive gear wheel ( 17 ).
3. Install the complete drive gear wheel
into the differential carrier ( 3 ) .
4. Put on the drop gear housing ( 7 ) and
bolt it .
5. Tighten the thread ring ( 18 ) until
there is a bearing roll resistance of 1.0
Nm , measure the bearing roll
resistance by using a torque wrench .
Back off the thread ring 2 teeth .
6. Bolt the lock plate ( 19 ) for the thread
ring with screws ( 20 ) , secure with
Loctite 270 , if need be bend the lock
plate .
Detach drop gear housing and drive
gear wheel .
 Service Manual 4.9.4

Assembly and bearing adjustment of the drive pinion with drop gear

1. Install the drive pinion ( 1 ) with taper roller

bearing into the differential carrier ( 3 ) .
2. Push the side gear wheel ( 21 ) onto the drive
pinion .
3. Install the spacer rings (22 + 23 ) onto the drive
pinion .
4. Put the drop gear housing ( 7 ) with mounted
outer ring of the taper roller bearing onto the
differential carrier ( 3 ) and bolt it.
5. Install the outer taper roller bearing (4 ) onto
the drive pinion.
6. Tighten the safety nut ( 2 ) . Adjust the roll
resistance of the taper roller bearings to about
1,5 to 1,8 Nm by modification of the thickness
of the spacer ring (23). Measure the roll
resistance of the bearings by using a torque
wrench .
Attention :
Block the side gear wheel while tightening the
safety nut .
7. Detach the drop gear housing .
8. Install the drive gear wheel ( 17 ).
9. Coat the contact surface of the differential
carrier with Epple 33 or Loctite 510 , put on the
drop gear housing and bolt it .
10. Tighten the safety nut . The locking ring on the
stake nut has to be sheared to allow a locking
tab to be tapped into the retaining slot of the
drive pinion . Loctite 262 on the thread .
11. Put the cover ( 24 ) coated with Epple 33 or
Loctite 510 onto the drop gear housing and bolt
it . ( Install the cover after the gear meshing
adjustment has been completed.)
 Service Manual 4.20.4

Differential installation

1. Install the o - rings ( 1 + 2 ) , thread rings ( 3 + 4 ) and outer rings of taper roller bearings
( 5 + 6 ) into the bearing housings ( 7 + 8 ) .
2. Mount the bearing housing ( 7 ) onto the differential carrier ( 9 ) and place the pre - assembled
differential into the differential carrier .
3. Mount the bearing housing ( 8 ) onto the differential carrier .
4. By counter rotating the two thread rings , move the differential until the backlash is correct .
(The value at the narrowest place is written down on the ring gear ) .
Hold the drive pinion at the drive flange . Check the backlash by rotating the ring gear .
Use a dialindicator .
(Gear meshing and backlash is to be checked according to sheet “adjustment of gear meshing
of Gleason gears “, page 4.0.1 at the end of this manual) .
5. Adjust the bearing roll resistance through tightening of the thread rings .
Check the value with a torque wrench and set to 2.5 - 3.5 Nm . If this value is taken at the drive
pinion / drive flange , take the ratio of the bevel wheel set into account .
6. Lock the thread rings with the cheese head screws , secure with Loctite 270 .
 Service Manual 4.20.5

Assembly of the differential lock

1. Coat the thread of the thread bushing ( 1 ) with Loctite 262 , attach shim ( 2 ) and screw the
thread bushing into the shifter fork ( 3 ) , tightening torque MA = 250 Nm .
2. Place the shifter fork and the shift collar ( 4 ) into the bearing housing ( 5 ) , attach the spring (
6 ) and install the rod ( 7 ) into the differential carrier ( 8 ) .
3. Coat the ring groove of the piston ( 9 ) for the O - ring ( 10 ) with Klüber special grease
Microlube GL 261 , mount the O - ring ( 10 ) onto the piston and place the piston onto the rod.
4. Coat the piston thread in the shifter cylinder ( 11 ) with Klüber special grease Microlube GL 261
, place the O - ring ( 12 ) into the slot of the shifter cylinder , fit shifter cylinder ( caution : do
not damage the piston thread ) and bolt it , tighten the screws to 25 Nm .
5. Mount the switch ( 13 ) with the seal ring ( 14 ) .
6. Check the differential lock for function and tightness .
Changing of the O - ring :
1. Detach the shifter cylinder ( 11 ) .
2. Change the O - ring .
3. Mount the shifter cylinder with a new O - ring ( 12 ) .
4. Check the differential lock for function and tightness .
 Service Manual 4.32.2

Assembly of the axle disconnect

1. Coat the ring grooves of the piston ( 1 ) for the O - ring ( 2 ) resp. piston guide band (3 )
with Klüber special grease Microlube GL 261 . Mount the O - ring ( 2 ) with the aid of the
service tool (see page 3.6.2/3 at the end of this manual) , put the piston guide band ( 3 )
into the slot of the piston (1) . Coat the thread of the piston ( 1 ) with Loctite 262 .
2. Install the spring ( 4 ) onto the piston ( 1 ) and insert the shifter fork ( 5 ) into the opening
in the shifter housing ( 6 ) . Guide the piston ( 1 ) through the shifter fork ( 5 ) and screw
the piston into the shifter fork by using the service tool ( see page 3.6.2/3 ) . Tightening
torque = 150 Nm .
3. Coat the piston thread in the shift cylinder ( 7 ) with Klüber special grease Microlube GL
261 , coat the contact surface of the shift cylinder ( 7 ) with Loctite 572 . Mount the shift
cylinder (7) ( Attention : do not damage the piston tread), tighten the screws to 49 Nm .
Mount the switch ( 8 ) with the seal ring ( 9 ) .
4. To assemble, slide the shift collar ( 10 ) onto the shaft, then feed the shaft through the
upper drop gear into the drive flange . Place the shift control assembly on the differential
housing while introducing the shifter fork (5) into the slot of the shift collar (10 ) . Seal the
shifter housing (6 ) with Loctite 510 . Fit the shiftcontrol bolts, torque to 25 Nm .
5. Screw in the set screw ( 11 ) coated with Loctite 270, into the differential carrier and
adjust measurement to 30 mm. ( see sketch )
6. Check the shift control for function and tightness .
Changing of the O - ring ( 2 ) and the piston guide band ( 3 ) :
• Remove the shifter cylinder ( 7 ) .
• Change the O - ring ( 2 ) and the piston guide band ( 3 ) .
• Coat the contact surface of the shifter cylinder ( 7 ) with Loctite 572 and mount shifter
cylinder ( 7 ).
• Check the shift control for function and tightness .
 Service Manual 4.32.3

Assembly of the through drive shaft

Tighten the safety nut at the drive flange . This is a M30 x 1.5 nut which needs to be torqued
to 450 Nm.

Lock the nut by striking the nut brim into the slot of the through drive shaft .
 Service Manual 2502

Pre - assembly of the input shaft

1. Heat the gear wheel ( 1 ) to about 120° C and install it onto the input shaft ( 2 ) , while
observing the alignment of the bolt holes . Install and tighten the screws ( 3 ) , secure the
screws with Loctite 262 .
2. Heat the inner rings of taper roller bearings ( 4 + 5 ) to about 100° C and install them onto
the input shaft ( after cooling drive on for contact ) .
 Service Manual 2503

Pre - assembly of the intermediate shaft

• Heat inner rings of cylindrical roller bearings ( 1 + 2 ) to about 100° C and install them onto the
intermediate shaft ( after cooling drive on for contact ) .
 Service Manual 2504

Pre - assembly of the output shaft with differential

Refer to the drawings on next page 2505

1. Heat the taper roller bearing inner ring ( 1 ) to about 100° C and install it onto the ring
gear carrier ( 2 ) ( after cooling, drive on for contact ) .
2. Install outer ring of needle bearing (3 ) into the ring gear carrier and install the circlip (4).
3. Press in taper roller bearing outer ring ( 5 ) into the ring gear carrier .
4. Place the ring gear ( 7 ) onto the ring gear carrier and install the circlip ( 8 ) .
5. Heat the taper roller bearing inner ring ( 5 ) to about 100° C and install it onto the flange
(9 ) ( after cooling , drive on for contact ) .
6. Press needle bearing inner ring ( 3 ) onto the flange ( 9 ) and install the circlip ( 10 ) .
7. Press the thrust ring ( 11 ) with Loctite 270 applied into the flange ( 9 ) .
8. Push in the needle bearings ( 12 ) into the planetary gears ( 13 ) .
9. Press the planetary pins ( 14 ) into the flange ( 9 ) , place on the thrust washers ( 15 ) and
push on the pre - assembled planetary gears . Install the thrust washers ( 16 ) and install
the sun gear (17).
10.Install the shim ( 23 ) ( if present ) .
11.Press the gear wheel ( 19 ) onto the flange ( 9 ) , coat the contact surface with Loctite
270, install and tighten the screws ( 21 ) , secure with Loctite 262 . Check the planetary
gears for easy running .
12.Heat the taper roller bearing inner ring ( 22 ) to about 100° C and install it onto the gear
wheel ( 19 ) ( after cooling , drive on for contact ) .
13.Slide the ring gear carrier with inner-ring gear onto the pre - assembled differential .
Service Manual 2505
 Service Manual 4.32.4

( for the following descriptions see sketches on page 4.32.5 )

Pre - assembly of the gear housing

1. Place the oil pipe ( 1 ) into the gear housing ( 2 ) and bolt it , secure the screws with Loctite 270.
2. Press in outer ring of taper roller bearing ( 3 ) , attach shim ( 6 ) and press the outer ring of
taper roller bearing ( 4 ) into the housing ( 7 ) .
3. Mount the oil pump housing ( 5 ) .
4. Bolt the housing ( 7 ) onto the gear housing .

Bearing adjustment, in- and output shaft

1. Place input shaft and output shaft into the pre-assembled gear housing which is to be in a
horizontal position .
2. Press in outer rings of taper roller bearings ( 9 + 10 ) .
3. Put on the gear housing ( 8 ) , knock in the dowel pins and tighten the screws .
4. Install the shim ( 11 ) and bolt the cover ( 12 ) to the gear housing .
5. Turn the gearbox into the vertical position .
6. Adjust the roll resistance of the input shaft bearing to 4 Nm by grinding of the shim ( 11 ) ,
after that adjustment decrease the thickness of the shim by about 0,35 mm .
7. Adjust the roll resistance of the output shaft bearing to 4 Nm by grinding of the shim ( 6 ) ,
after that adjustment decrease the thickness of the adjusting disk of about 0,14 mm .
Service Manual 4.32.5
 Service Manual 2508

Assembly of the intermediate shaft

1. Press the cylindrical roller bearing outer rings ( 1 + 2 ) into the gear housings ( 3 + 4 ) .
2. Place the intermediate shaft ( 5 ) into the gear housing .
3. Install and bolt the covers ( 6 + 7 ) onto the gear housings , sealing with Loctite 510 , secure
the screws with Loctite 262 .
 Service Manual 4.32.6

( For the following description see sketch on page 4.32.7 )

Assembly of the transfer case

1. Install and bolt the oil baffle ( 1 ) , secure the screws with Loctite 270 .
2. Coat the contact surface of the gear housing ( 2 ) with sealing compound , lay on the gear
housing ( 3 ) , knock in the dowel pins and bolt the housings .
3. Press the radial seal ring ( 4 ) with Loctite 572 ( rubber cage ) resp. Loctite 270 ( steel cage )
applied into the cover ( 5 ) . Fill the radial seal ring with bearing grease .
4. Press the radial seal ring ( 6 ) with Loctite 572 ( rubber cage ) resp. Loctite 270 ( steel cage )
applied into the housing ( 7 ) . Fill the radial seal ring with bearing grease .
5. Place the cardan screws ( 8 + 9 ) into the drive flanges ( 10 + 11 ) and slip on the drive flanges
onto the input shaft ( 12 ) resp. output shaft ( 13 ) . Screw on the stake nuts (14 + 15) with
sealing compound between the contact surfaces . Tighten the stake nuts according to the
torque figures on sheet 3.5 . The locking ring on the stake nuts has to be sheared to allow a
locking tab to be tapped into the retaing slot of the shafts .
Service Manual 4.32.7
 Service Manual 4.32.8

Assembly of the differential lock

1. Install the sliding sleeve ( 8 ) with shifter fork ( 5 ) into the gear housing .
2. Coat the ring grooves of the piston ( 1 ) for the O - ring ( 2 ) resp. piston guide band ( 3 ) with
Klüber special grease Microlube GL 261 . Mount the O - ring ( 2 ) and put the piston guide
band ( 3 ) into the slot of the piston ( 1 ) . Coat the thread of the piston ( 1 ) with Loctite 262 .
Coat the piston tread with Klüber special grease Microlube GL 261 . Feed the spring ( 4 ) onto
the piston ( 1 ) . Guide the piston ( 1 ) through the shifter fork ( 5 ) and screw the piston into the
shifter fork by using the service tool (p/n 038.125.0-3 / 038.126.0-4 see page 3.6.2/3)
Tightening torque = 150 Nm .
3. Coat the piston bore of the shift cylinder ( 6 ) with Klüber special grease Microlube GL261 ,
coat the contact surface of the shift cylinder with Loctite 572 . Mount the shifter cylinder
( Attention : do not damage the piston surface ) . Mount the switch ( 7 ) .
4. Check the differential lock for function and tightness .
Changing of the O - ring ( 2 ) and the piston guide band ( 3 )
• Remove the shifter cylinder ( 6 ) .
• Change the O - ring ( 2 ) and the piston guide band ( 3 ) .
• Coat the contact surface of the shift cylinder with Loctite 572 and mount shift cylinder .
• Check the differential lock for function and tightness .
 Service Manual 4.32.9

Assembly of the oil pump

1. Place the ball ( 1 ) into the input shaft ( 2 ) ⇒ observe the marking ( M ) at the end face .
2. Turn the gear wheel ( 4 ) of the oil pump ( 5 ) until the drive slot aligns with the notch in the
carrier plate ( 6 ) .
3. Slide the pre - assembled oil pump onto the input shaft .
4. Install the cover ( 7 ) onto the pump housing ( 8 ) and bolt together, seal with sealing
compound .
 Service Manual 4.32.10

Finish assembly drive assembly

1. Measuring of the through drive shaft axial clearance

Measure dimension “A” between gear contact surface and sun gear of the interaxle differential
.
Measure dimension “B” between gear contact surface and circlip of the through drive shaft .
Calculate the axial clearance ( set value 0,3 to 0,5 mm )
dimension “A” minus “B” = axial clearance .
2. Install the plate ( 1 ) , sealing with sealing compound Dirko-grey .
3. Coat the contact surface of the gear housing with sealing compound , put together the gear
box, knock in the dowel pins and bolt the housings .
 Service Manual 4.0.1

Adjustment of gear meshing of Gleason gears

Perfect marking .

The figures below show improper gear meshing marks . The text alongside indicates
which corrections are needed to obtain correct gear meshing. Adjust the related gear
in the direction of the black arrow; if any additional adjustment is required, make a
further adjustment with the other gear in the direction of the white arrow
( The figures show the ring gear ) .

Increase the backlash .

If the correction of the ring gear is insufficient ,
back-off the drive pinion from the ring gear .

Decrease the backlash .

If the correction of the ring gear is insufficient ,
move the drive pinion to the ring gear .
Service Manual 3.6.2/3

Service tools
Assembly cone for o - ring
( differential lock )

Assembly sleeve for piston

( differential lock )
 Service Manual 3.3
Tightening torques ( Nm )
µ = 0,14

Metric standard thread

Screw Nut Screw Nut Screw Nut

Thread 8.8 8 10.9 10 12.9 12
M4 3,0 4,4 5,1
M5 5,9 8,7 10
M6 10 15 18
M8 25 36 43
M 10 49 72 84
M 12 85 125 145
M 14 135 200 235
M 16 210 310 365
M 18 300 430 500
M 20 425 610 710
M 22 580 830 970
M 24 730 1050 1220
M 27 1100 1550 1800
M 30 1450 2100 2450
Metric fine pitch thread
Screw Nut Screw Nut Screw Nut
Thread 8.8 8 10.9 10 12.9 12
M8x1 27 39 46
M 10 x 1 55 81 95
M 10 x 1,25 52 76 90
M 12 x 1,25 93 135 160
M 12 x 1,5 89 130 155
M 14 x 1,5 145 215 255
M 16 x 1,5 225 330 390
M 18 x 1,5 340 485 570
M 20 x 1,5 475 680 790
M 22 x 1,5 650 920 1050
Brake caliper dowel screws ( greased ! )

M 20 x 1,5 400 + 100

M 27 x 2 900 + 100
Nut for steering stop = 300 Nm

Apply a reduced tightening torque for galvanized bolts and nuts !

 Service Manual 3.5

Tightening torque of lock nuts of drive flanges , gearwheels ect.

Thread Torque
d1 ( mm ) ( Nm )

M 24 x 1,5 360

M 30 x 1,5 450

M 36 x 1,5 540

M 42 x 1,5 850

M 45 x 1,5 850

M 48 x 1,5 850

M 52 x 1,5 950

M 64 x 1,5 1050 - 1100

 Service Manual 4.0.2

Securing the stake nut

Loosen

The locking ring on the stake nut has to be sheared to allow a locking tab to be tapped into
the retaining slot.
.

Use of Loctite and other consumables

1.) Stake nut at drive flange
- In thread : assembly paste with MoS2 ( exception through drive pinion see point 2 ) .
- Front side contact surface : sealing compound ( Epple 33 or equivalent ) .
2.) Stake nut at through drive pinion
- In thread : Loctite 262 .
3.) Stake nut at gear wheels , bearings etc.
- In thread : assembly paste with MoS2 .

Removal of the stake nut

Prise the locking tab out of the retaining slot and screw off the nut.