"Differential, Overhaul
 Disassemble Disassemble differential: Detach both tapered roller bearing inner races (5) with KM-161-A (1), Hooks KM-161-3 (2) and Thrust Piece KM-403 (3), if necessary unscrew remover hooks from counter support and fit individually on bearing. AF 20 only: remove speedometer helical gear driving (5) - is not reinstalled on assembly (if still present). For all transmissions: Drive gear, driven, (9). Mark position of drive gear relative to differential housing (8). Release retaining plates (7) with screwdriver. Remove 8 bolts. Detach drive gear, if necessary with plastic hammer. | 
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 Remove, Disconnect Remove cylinder pin (1) with drift. Remove bevel gear axle (2), differential pinions with thrust washers (3) from installation opening by turning one of the two axle shaft gears. Remove axle shaft gears with thrust washers (4).
 Inspect Check inner parts of differential for damage and wear, if necessary, replace assembly - re-use drive gear (driven).
Remove, Disconnect Drive both axle shaft seal rings from the inside out of main or auxiliary housing using screwdriver (if not yet removed). Detach both tapered roller bearing outer races together with the thrust washers - KM-210-A (5), KM-709 (6, 7 and 8), remover hooks grip in the recess under the thrust washer. Before detaching (tool inserted as described and slightly pre-tensioned). Heat housing with hot air blower to approx. 80 ° C. | 
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 Assemble Assemble differential: Press in both tapered roller bearing outer races with thrust washers - use KM-695 or KM-710 (2) and KM-305 (1). Thrust washer thickness for bearing in auxiliary housing: 2.5 mm. For new bearings for the outer race in the main housing, use the smallest washer thickness - see "Aftersales" microfiche. If no damage can be seen on the inner parts: Insert axle shaft gears with thrust washers (5 and 7) into differential. Align differential gears (4 and 6) and thrust washers with bore for bevel gear shaft by turning at one of the axle shaft gears. Insert bevel gear shaft (3) into differential. Drive cylinder pin into bevel gear shaft and secure by centre punching at bore edge. | 
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 Install, Connect Attach gear (driven) to differential housing - heat in fluid to approx. 100 ° C. Place driving gear immediately onto differential housing, note mark (2) made on removal. Drive gear, driven, (3) tightening torque - 100 Nm / 74 lbf. ft., use new retaining plates (1 and 4) and bolts, secure bolts. Press on both tapered roller bearing inner races (5) and (6) with KM-697 (7).
 Important! Small bearing outside diameter (6) on differential housing side. On assembly omit speedometer gear (if still present), as there is no speedometer drive present. | 
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 Adjust Adjust pre-tensioning of the differential tapered roller bearing. Place differential in main housing. Auxiliary housing to main housing, Tightening torque - 30 Nm / 22 lbf. ft., 11 bolts, note centring pin (arrow).
 Measure Measure starting torque of differential without gear set with KM-J-28544-A (2) - see also section "Special Service Tools" - and MKM-536-A (1).
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Measurement value: |
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New bearing: 0.7 to 1.2 Nm / 0.5 to 0.9 lbf. ft. |
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Run-in bearing: 0.35 to 0.6 Nm / 0.2 to 0.4 lbf. ft. |
Correct by selecting suitable thrust washers under tapered roller bearing outer race of the main housing (available washers: see Aftersales microfiche). | 
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Remove, Disconnect Auxiliary housing, differential, if necessary tapered roller bearing outer race of main housings (only if adjustment is necessary).
Install, Connect After adjustment of the pre-tensioning: drive in axle shaft seal rings with KM-519 up to stop. | 
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