Final Drive Surgery with Pics

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motoleo
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Re: Final Drive Surgery with Pics

Post by motoleo » Wed Sep 18, 2013 8:21 am

BinDerSmokDat wrote:ReCycled just left...

:party: The FD is assembled and the case bolted back up! :party:

I'm exhausted. I'll get a few new pics up tomorrow.

Big, big thanks to Dave. He was a huge help.
He's still be driving home as I post his, he left looking more than a little tired.
Nice Job! :boogie: Glad you got it done in time to get on the road for this weekend. Now I know who to call if I have trouble with mine.
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BinDerSmokDat
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Re: Final Drive Surgery with Pics

Post by BinDerSmokDat » Wed Sep 18, 2013 8:28 am

motoleo wrote: Now I know who to call if I have trouble with mine.
Yeah...

Dave! :lol:

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Re: Final Drive Surgery with Pics

Post by motoleo » Wed Sep 18, 2013 8:39 am

BinDerSmokDat wrote:
motoleo wrote: Now I know who to call if I have trouble with mine.
Yeah...

Dave! :lol:
2 heads are better than 1!
motoleo
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94 Ural Tourist (sidecar waiting to be done)
?? Dnepr MT-11 project
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BinDerSmokDat
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Re: Final Drive Surgery with Pics

Post by BinDerSmokDat » Wed Sep 18, 2013 8:58 am

OK as I'm going through my pics, there is some stuff I didn't post yet and is out of order.

New pinion seal, with old pinion seal (spring fell out) and pinion bearing nut...


Image


New inner pinion race. There is a slight bevel at the bottom edge. The bevel goes on the tip, the flat edge against the teeth.
Set the race on a hard flat surface and tap the pinion in.


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Image

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Next place the pinion in the freezer with your Jimmy Dean sausage sammiches.
In the meantime, set the 3304 bearing on a top of a hottish location.
Remember the stock bearings have polymer races, don't get them too hot.
I set mine on top of my bench light, which was reading about 200F. Leave both there for about 15 minutes.
Then with gloves, place the hot bearing on a vice so the vice jaws support the inner race.
Slip the pinion shaft into the bearing. Done this way, minimal tapping should be required to seat it.


Image

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Next is the ring gear. It slips on the splined hub easily, but once on it doesn't move, so you have to put it on with the holes perfectly aligned.
If you put the ring gear on and it doesn't line up, just invert it and tap the splines on the bench, the ring will pop off.
Lather, rinse, repeat until the holes line up.

Image

Image

Install the bolts with red loctite...

Image

There was some discussion about installing the bolts with the flat sides towards the edge.
I think that is a hold over from the metal clip days as far as the stock bolts (12mm heads) are concerned.
The bolt heads easily clear the outer bearing race, whether the corners or the flats are oriented towards the edge.
The aftermarket bolts which have 13mm heads also clear the race, but with slightly less clearance.
We assembled mine with 5 of the 8 bolts not aligned with the edge towards the race and it wasn't a problem.
But the anal retentive side of me later realigned them with the flats towards the race. :lol:

Here is the pinion and drive shaft slipped together, the outer bearing race and needles installed on the pinion. The old inner race is visible lower right. Note it is darker from lots of heat applied to remove it.
It was really an exercise in futility, because there was no way I was going to reuse it once I saw how much force and heat was used to remove it.
If you are replacing the pinion gear, replace the pinion bearing, don't even bother trying to remove the old inner race.

Image

Here is the gear set-up compound...

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Here is the mesh engagement pattern on the ring gear...looks pretty good.

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And here is what the pinion gear looks like. I re-used the stock shim on the pinion gear.

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I don't have pics from the rest of the final assembly.
If someone wants to use the pics and organize them in order, be my guest.
Again, I'd like to thank all the little people...

Herve Villechaize
Verne Troyer
Joe C.

Because let's face it, midgets are funny.

I'd also like to thank...
Billy G for his excellent site (without which I wouldn't even have attempted this rebuild)
ReCycled for his help, moral support and level headed words when I get impatient and just want to wail on it with a hammer.
And all the rest of you mugs for the encouraging words and suggestions.

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BinDerSmokDat
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Re: Final Drive Surgery with Pics

Post by BinDerSmokDat » Wed Sep 18, 2013 9:08 am

One other thing. Billy G's site mentions that the pinion needle bearing is 28 needles and the splined hub needle bearing is 49 needles.
On my bike I had 29 and 50 needles respectively.
The "new" replacement pinion needle bearing had 28.

The bearings were apparently upgraded with an extra needle at some point.
The outside fit dimensions are otherwise the same.
If you feel you absolutely need the extra needles, make sure you are ordering from a new parts list.
And if ordering from one of the big parts suppliers who may have stock sitting for a few years, verify with them that you are getting the new bearing and not the older equivalent.

I personally don't think it's a big issue, as the needles and inner races dimensions are appropriate for the number of needles.
There is no "gap" that the 29th needle fills; both bearings assemble with the needles properly spaced inside their respective races.

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Re: Final Drive Surgery with Pics

Post by Bryan Wilson » Wed Sep 18, 2013 9:52 am

Terrific post and photos You have great patience to tackle re-build and document the whole thing ,followed it with great
interest. Iam worn out gotta have beer. Welldone :beerchug:
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rebelpacket
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Re: Final Drive Surgery with Pics

Post by rebelpacket » Wed Sep 18, 2013 10:11 am

Great thread!! :clap:

Lots of good info in here.
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Re: Final Drive Surgery with Pics

Post by Albuquralque » Wed Sep 18, 2013 10:20 am

Great write up and pics! Thanks BDSD! :boogie:

Now keep us posted on how it is when you ride.
"Put a little gravel in your travel"

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Re: Final Drive Surgery with Pics

Post by Lokiboy » Wed Sep 18, 2013 11:00 am

When I get back in the states, I'll reconfigure the post and add to the "Best of" thread. Thanks for the great pictures and clarification on the mislabeled bearings in the parts book.
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Re: Final Drive Surgery with Pics

Post by MartyL » Wed Sep 18, 2013 11:40 am

Made into a sticky. Good info. Thanks for sharing! :)
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Re: Final Drive Surgery with Pics

Post by BinDerSmokDat » Wed Sep 18, 2013 1:12 pm

I'm actually in "Gobium mode" now...scouring sites for a blown 2WD FD to rebuild as a spare.

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BinDerSmokDat
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Re: Final Drive Surgery with Pics

Post by BinDerSmokDat » Thu Sep 26, 2013 8:57 am

Hey guys just a little update...

I bolted things up, filled with oil and then did what every good final drive break-in requires...
I rode the Jersey Devil Hunt off-road for two days, plus road miles there and back...maybe a few hundred miles total. :D

Here is the drain plug on the first change after the rebuild right after I got back form the JDH...

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And here was my first FD change when the bike only had 600km on the clock...

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They look comparable. I'll keep an eye on it. I've always changed the FD at 2500km or sooner when dunked.
My initial FD issue was stress, not lubrication related, so I don't see any need to change things.

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Re: Final Drive Surgery with Pics

Post by Mr Wazzock » Thu Feb 23, 2017 5:56 pm

BinDerSmokDat wrote:I picked up these at Fastenal while I was ordering new bolts. :D A lifetime supply!
Image

Thanks for this. Silly service manual seems to omit to mention what size the washers are...


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