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VG080 overhaul

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Gelande
Posts: 5327

Re: VG080 overhaul

Post#21 » Sat Jun 29, 2019 10:31 am

Excellent write up and effort great pics too thank you !!

On the flange installs Chris and I found that about 170-175 degrees in the oven or in our case an old toaster oven would get them to slide on pretty easy. Never pry on or hammer on a flange, never use one you dropped on the ground either. They can go out of balance quite easy with small damage. When they are off your truck, store them wrapped up in a piece of bubble as the alloy can ding fairly easy (like if it slides off a table or workbench by mistake, or off a shelf).

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cal_w460
Posts: 2205

Re: VG080 overhaul

Post#22 » Sat Jun 29, 2019 1:25 pm

Thanks for the info. I stored them in a cardboard box wrapped in paper during the restoration of the box.

But are you 100% sure that you heated the flanges to 170-175 degree C?

The Workshop Manual says that the flanges should be heated to approx. 120 dgr. C and not more than 140 dgr. C.

One problem with sliding the hot flanges all the way in is that you will push a heated flange into the two rubber seal rings. Atleast the outer one. NBR can handle around 100-110 dgr C max. according to the specs, but that might be under long use?

There is a note in the Workshop Manual that says that the heated flange should be pushed onto the shaft just before it reaches the seal ring. Then let the flange cool off before continuing into the seal ring.

Problem is that if you follow this procedure and stop before tuching the radial seal. There will not be any threads visible for the nut to thread onto? Therefor the flange has to be pressed the last bit, wich requires opening the TC up and supporting the other side of the shaft to not damage the alloy housing.

Or can the seal rings handle 120 dgr. C without problems?
There must be a reason to not heat the flanges more though. (>140 C)

Personally I feel that there is a step missing between step 49 and 50 in the WSM.

image.jpeg
w460.333 1982 Colorado Beige 300 GD OM617.931

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cal_w460
Posts: 2205

Re: VG080 overhaul

Post#23 » Sat Jun 29, 2019 1:59 pm

The original Workshop Manual says nothing about avoid touching the seal rings with the heated flange. Those instructions are from WIS.

A bit contradictory information. :roll:

VG080_Flange_Install.JPG
w460.333 1982 Colorado Beige 300 GD OM617.931

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cal_w460
Posts: 2205

Re: VG080 overhaul

Post#24 » Sat Jun 29, 2019 2:04 pm

This is probably the reason to not heat the flange above 120 dgr. C.

The permissible operating temperature range of Nitrile Rubber is –40 to +100 °C (–40 to +210 °F). For brief periods, temperatures of up to 120 °C (250 °F) can be tolerated.


Source: SKF (https://www.skf.com/group/products/seal ... index.html)
w460.333 1982 Colorado Beige 300 GD OM617.931

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Gelande
Posts: 5327

Re: VG080 overhaul

Post#25 » Sat Jun 29, 2019 4:26 pm

Yes I can not remember the actual temp, it was whatever the service book noted.

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cal_w460
Posts: 2205

Re: VG080 overhaul

Post#26 » Mon Jul 01, 2019 9:24 am

Thanks Gelande!

Today I heated the flanges to 120 dgr. C. However, they were still tight. I got them 15-16mm onto the shafts by hand. Then I used a hydraulic press with a wooden support behind the shaft and a wooden support for the flange. And pressed them on until there was enough threads for the nuts.

This box isn't very complicated. But there is a bit of work getting these flanges on and off. The output flange for the rear axle needs to be removed with a pneumatic socket gun or similar.

Time to install the box under the G again.

I replaced the TC mounts with new OEM rubber bushings bought from Kurt here on the forum. Used the OEM bushing tool / press to remove the old bushings and press in the new ones. Quick job done in 10 minutes or so.

Life is so much easier with the right tools. :)
w460.333 1982 Colorado Beige 300 GD OM617.931

jtrein
Posts: 496

Re: VG080 overhaul

Post#27 » Mon Jul 01, 2019 1:03 pm

I use this Horrible Freight transfer pump for adding fluid to my diffs, transmission or TC. One hose goes into the container of whatever I am filling and the other goes into whatever is getting filled. The hoses are long so nothing can fall off inside and I don't have to worry about making a mess spilling any of the fluid as I can just hold both ends up when it is full and drain them back into the container. The only thing to watch out for is to make sure you press the ends into the pump nice and tight so they don't fall out or shoot out while transferring fluid. I keep one of these in my G all the time, they are super cheap and I have used the same pump a number of times and it still works as it should.
Attachments
transfer pump.PNG
1981 280GE Ambulance - full restoration in progress
1985 280GE

User avatar
cal_w460
Posts: 2205

Re: VG080 overhaul

Post#28 » Mon Jul 01, 2019 1:16 pm

Nice. Seems like a real bargain. I have a metal pump that usually works fine when doing oil changes in engines, transmissions, diff housings and such as long as the temperature is above +5-10 dgr. C or so.

Problem was that I changed TC oil outside when it was around 0 dgr. C cold. And the GL4 transmission fluid became very thick. The pump didn't work. So I switched to a syringe with a 10cm hose. Wich blew off.

Anyway. It feels good to have cleaned up the TC, checked the condition of all internal bearings and shafts, replaced all radial seals (wich are becoming harder and harder to buy. OEM is NLA.), treated it with some fresh 2k paint and soon assemble it in the G with new TC mounts and an A-brace.
w460.333 1982 Colorado Beige 300 GD OM617.931

jtrein
Posts: 496

Re: VG080 overhaul

Post#29 » Tue Jul 02, 2019 6:19 am

cal_w460 wrote:Nice. Seems like a real bargain. I have a metal pump that usually works fine when doing oil changes in engines, transmissions, diff housings and such as long as the temperature is above +5-10 dgr. C or so.

Problem was that I changed TC oil outside when it was around 0 dgr. C cold. And the GL4 transmission fluid became very thick. The pump didn't work. So I switched to a syringe with a 10cm hose. Wich blew off.

Anyway. It feels good to have cleaned up the TC, checked the condition of all internal bearings and shafts, replaced all radial seals (wich are becoming harder and harder to buy. OEM is NLA.), treated it with some fresh 2k paint and soon assemble it in the G with new TC mounts and an A-brace.


I see, changing oil in the cold can be problem!
1981 280GE Ambulance - full restoration in progress
1985 280GE

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cal_w460
Posts: 2205

Re: VG080 overhaul

Post#30 » Wed Jul 03, 2019 3:41 am

Next time I will pre heat the GL4 oil and keep it in an insulated canister while pumping. ;)
w460.333 1982 Colorado Beige 300 GD OM617.931

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