|
Differential, Overhaul (Transmission Installed)
These operations are to be executed with the transmission
installed.
See "Transmission and Differential, Overhaul" for
additional information.
Remove and Disassemble
Raise vehicle. Remove both front wheels.
Unscrew differential cover from transmission housing (fluid
will drain out).
Unbolt swivel joint from both sides of steering knuckle.
Drive both shafts out of transmission housing with
KM-460-A-2 (left side, modified tool) and KM - 460 - A - 1 (right
side).
|
|
Important:
The chamfered side of the tools must always face the
transmission.
Suspend drive shafts immediately, do not allow to sag.
Mark the bearing ring and the transmission housing to
indicate their relative position. Check for play in tapered roller bearings.
Turn bearing ring out of transmission housing using
KM - 477 and remove differential.
Unscrew locking plate from bearing ring.
Clamp differential housing in vice using
KM - 458 - A.
Drive both seal rings out of bearing ring and transmission
housing using KM - 454 - A - 2 and - 4.
Drive tapered roller bearing outer races out of bearing ring
and out of transmission housing using KM - 305 and
KM - 451 (KM - 303 underneath).
Remove 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.
Knock off speedometer helical gear (driving) from
differential housing (destroy).
Unbolt ring gear (driven) from differential housing and knock
off with brass drift.
Only replace ring gears in pairs (driving and driven).
Remove left and right retaining rings from differential
pinion shaft.
Use drift to drive pinion shaft out of differential housing.
Turn differential pinions and side gears out of differential
housing.
Assemble and Install (Transmission Installed)
Clean all removed parts, check for wear and replace if
necessary. Prior to assembly coat sliding surfaces of bevel gear axle, bevel
gears and disc springs with Transmission Fluid
19 40 750 (90 001 777).
Mount side gears, differential pinions, disc springs and
pinion shaft in differential housing.
Premount using KM-456.
Bolt drive gear to differential housing - important
connection, 85 Nm/63 lbf. ft.
Important:
Heat drive gear to 80 °C/176 °F (use thermocolour
pensils or suitable temperature gauge).
Drive new speedometer helical gear (driving) onto
differential housing using KM - 459.
Important:
Preheat helical gear and KM-459 in water bath to
80 °C/176 °F (use thermocolour pencils or suitable temperature
gauge).
Press both tapered roller bearing inner races onto
differential housing using KM - 453 (2 parts).
Press tapered roller bearing outer race into transmission
housing using KM - 120 - 2 and - 3, as well as
KM - 451.
Tap bearing outer race gently in case when doing this.
Press tapered roller bearing outer race into bearing ring
using KM - 304 and KM - 451.
Use KM-446 to drive two new drive shaft seal rings flush into
bearing ring and transmission housing.
Insert differential into transmission housing.
Turn bearing ring into transmission housing using
KM - 447.
When doing so, observe the adjustment instructions for tapered
roller bearings in differential under Sections d), e) or f).
Tighten bolt cover for differential at transmission housing -
30 Nm/22 lbf. ft. (sheet-metal version), 18 Nm/13 lbf. ft. (light
alloy version).
First, press both axle shafts into transmission housing. Then
drive in with screwdriver on friction weld joint until the retaining ring snaps
into place.
First insert new retaining ring in axle shaft.
Important:
Do not overstress out retaining ring.
When retaining ring snaps into place, check proper seating of
axle shaft by pulling by hand at widest point of joint.
Important:
Proper seating of axle shaft cannot be checked by pulling shaft.
Fasten swivel joint with bolt and nut to steering knuckle - important
mounting part.
Observe prescribed torque - 30 Nm/22 lbf. ft.
Use new nut.
Tighten wheel bolts alternating crosswise and observe
prescribed torque - 11 0 Nm/81 lbf. ft.
Fill transmission fluid.
