Differential, Assemble and Install (F 10/F 15)
 Install, Connect F 10 transmission Insert axle shaft bevel gears into differential housing. Insert differential bevel gears with disc washers and pre-install with KM-456 and align. Screw axle shaft bevel gears and disc washers into differential housing. Drive bevel gear shaft into housing and fit new snap rings (engagement insert 12 commercially available). | 
|
F 15 transmission Immerse all parts in transmission fluid before installation. Fit plastic cage in differential housing.
 Important! Collar (1) of plastic cage must sit in guide for axle shaft bevel gears in housing. | 
|
Install, Connect Centre differential bevel gears with KM-456. Fit axle shaft and differential bevel gears, bevel gear shaft in differential and screw in. Install new retaining rings.
Important! | 
|
Ensure that retaining rings are correctly seated (see illus.). | 
|
Install, Connect Bolt drive gear onto differential housing. Use new bolts. For this, heat drive gear to approx. 80 ° C.
 Torque - Angle Method F 10 transmission: Drive gear to differential housing - 40 Nm / 30 lbf. ft. + 30 ° + 15 ° . F 15 transmission: Drive gear to differential housing - 70 Nm / 52 lbf. ft. + 30 ° to 45 ° .
Important! Always replace drive gears (driving and driven) in pairs. Note peripheral groove identification (arrows, see illus.). () = Number of grooves
| 
|
Install, Connect Clamp differential housing with KM-458-A in vice. Fit new speedometer helical gear to differential housing. For this, heat KM-459 and new helical gear in water bath to 80 ° C. Press speedometer helical gear onto housing with KM-459, at the same time the cams on the wheel must be flush with the recesses in the housing. Grease toothing with bearing grease. | 
|
Press inner races of tapered roller bearing onto differential housing using KM-453. | 
|
Install, Connect F 10, F 15. Drive both outer races of tapered roller bearing into transmission and bearing ring with KM-120-2 and KM-451 with transmission installed. With removed transmission, use KM-304 and KM-451 for both sides. | 
|
Drive both axle shaft seal rings in flush into bearing ring and transmission using KM-446. Sealing lip faces outwards. Fill spaces in seal lips with multi-purpose grease. | 
|
Install, Connect Insert differential into transmission casing. Screw bearing ring into transmission casing with KM-447. Coat thread and O-ring with multi-purpose grease. The connection must be oil-proof.
 Adjust Observe adjustment regulations for tapered roller bearing (differential) - see operation "Adjustment Regulations for Tapered Roller Bearing (Differential)".
Install, Connect | 
|
Secure bearing ring by bolting on locking plate - tightening torque 9 Nm / 6 lbf. ft. Insert respective closure plug into bearing ring and transmission casing. Bolt cover for differential to transmission casing with new seal. Sheet-metal version (F 10) - tightening torque 30 Nm / 22 lbf. ft., light-alloy version (F 15) - tightening torque 18 Nm / 13 lbf. ft. Install axle shafts - see operation "Axle Shaft Seal Rings, Replace". Check transmission fluid level - see operation "Transmission Fluid Level, Check". | 
|
|
