Differential, Overhaul
These operations are to be
carried out with main case installed.
See "Transmission and
Differential, Overhaul" for additional information.
Remove and Disassemble
Raise vehicle. Remove both
front wheels.
Unbolt differential cover from
main case (fluid escapes).
Press ball joints out of both
steering knuckles using KM-507-C.
F 10 and F 13 - Manual
Transmission
Drive both axle shafts out of
main case using KM-460-2-A (L.H. side, changed tool) and KM-460-1 (R.H. side)
(also for F 16 and F 20, except 18 E and 20 E engines).
Important: Chamfered side of tool must
always face transmission.
Use 1500 gram/3 1/2 lb hammer.
Suspend axle shafts immediately: do not allow
to sag.
Mark bearing ring and main
case with their relative positions. Check tapered roller bearings for play.
Unscrew bearing ring from main case using KM-447 and remove differential.
Clamp differential housing in
vice using KM-458-A.
Drive both seal rings out of
bearing ring and main case using KM-454-2 and -4.
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Drive
tapered roller bearing outer races out of main case and bearing ring using
KM-305 and KM-451 (place KM-303 underneath).
Pull
both tapered roller bearing inner races from differential housing using
KM-161-A in conjunction with Hook KM-161-3 and Pressure Piece KM-161-4.
Unbolt
ring gear from differential housing and knock off with brass drift.
Remove
L.H. and R.H. snap rings from differential pinion shaft.
Drive
pinion shaft out of differential housing using drift.
Screw
differential pinions and side gears out of differential housing.
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F
16 and F 20 Manual Transmission
Drive
both axle shafts out of main case using KM-503 (L.H. side) and with mounting
iron (R.H. side) - only with 18 E and all 2.0 litre engines.
Use 1500 gram/3 1/2 lb hammer.
Suspend axle shafts immediately: do not allow
to sag.
Mark
bearing ring and main case with their relative positions. Check tapered
roller bearings for play. Unscrew bearing ring from main case using KM-520.
Unbolt bearing flange and remove differential.
Press
both seal rings out of bearing ring and bearing flange using KM-466-3. Place
KM-466-2 underneath.
Clamp
differential housing in vice using KM-524-A (part 1).
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Press tapered roller bearing
outer race out of bearing flange and bearing ring using KM-304 and KM-451
(place KM-502-A underneath). Knock speedometer driving helical gear off
differential housing and discard gear.
Pull both tapered roller
bearing inner races from differential housing using KM-161-A in conjunction
with Hook KM-161-3 and Pressure Piece KM-161-4.
Unbolt ring gear from
differential housing and knock off with brass drift.
Remove fitted (retaining)
screws from differential housing (except F 20 manual transmission). Drive pin
(pinion shaft retainer) out of differential housing and pinion shaft (F 20
manual transmission). Remove pinion shaft from differential housing. Remove
differential pinions and side gears from differential housing.
Assemble and Install
F 10 and F 13 Manual
Transmission
Clean all removed parts and check for wear:
replace if necessary. Prior to assembly, coat sliding and contact surfaces of
pinion shaft, pinion and washers with Extreme Pressure Lubricant 19 70 300 (06
636 630).
Mount side gear, differential
pinion, washers and pinion shaft in differential housing.
Drive new speedometer driving
helical gear onto differential housing using KM-459.
Important: Heat helical gear and KM-459
to 80 °C/176 °F in water bath.
Bolt ring gear to differential
housing - important mounting part, - 70 Nm/51.63 lbf. ft.
Important: Heat ring gear to 80 °C/176 °F.
Press both tapered roller
bearing inner races onto differential housing using KM-453 (2 tools required).
Draw tapered roller bearing
outer races into main case using KM-120-2 and -3 in conjunction with KM-451.
To do this, tap bearing outer race gently into
housing.
Press tapered roller bearing
outer race into bearing ring using KM-304 and KM-451.
Drive both turbine shaft seal
rings flush into bearing ring and main case using KM-446.
Insert differential in main
case.
Screw bearing ring into main
case using KM-447.
When doing so, observe sections d), e) or f) of
adjustment instructions for tapered roller bearings in the differential.
F 16 and F 20 Manual
Transmission
Clean all removed parts and check for wear;
replace if necessary. Prior to assembly, coat sliding and contact surfaces of
pinion shaft, pinion and washers with Extreme Pressure Lubricant 19 70 300 (06
636 630).
Mount side gear, differential
pinion, washers and pinion shaft in differential housing.
Drive new speedometer driving
helical gear onto differential housing using KM-525.
Important: Heat helical gear with KM-525
in a water bath to 80 °C/176 °F.
Bolt ring gear to differential
housing - important mounting part, - 70 Nm/51.63 lbf. ft.
Important: Heat ring gear to 80 °C/176 °F.
Press both tapered roller
bearing inner races onto differential housing using KM-552 (2 tools required).
Press tapered roller bearing
outer races into bearing flange and bearing ring using KM-305 and KM-451. Press
both seal rings for axle shafts flush into bearing ring and bearing flange
using KM-519. Insert differential in main case.
Bolt bearing flange to main
case - 25 Nm/18.44 lbf. ft.
Screw bearing ring into main case
using KM-520.
When doing so, observe sections d), e) or f) of
adjustment instructions for tapered roller bearings in the differential.
Bolt cover for differential to
transmission housing.
Sheet metal cover: 30 Nm/22.1 lbf. ft.
Light alloy cover: 18 Nm/13.3 lbf. ft.
First press both axle shafts
into main case. Then drive in using screwdriver until snap ring snaps into
place.
Beforehand, mount new snap ring in
groove in joint stub shaft.
Important: Do not overload snap ring.
When snap ring snaps into place, check proper
seating of axle shaft by pulling by hand at outer diameter of joint.
Important:
Proper seating of axle shaft cannot be checked
by pulling shaft.
Fasten ball joint to steering
knuckle with castellated nut and secure with retaining clip - important
mounting part - 70 Nm/51.63 lbf. ft.
Tighten wheel bolts,
alternating crosswise - 90 Nm/66.38 lbf. ft.
Fill transmission fluid.
