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Differential, Disassemble and Assemble (AF 17)
 Remove
Remove differential – see operation "Differential, Remove
and Install (AF 17)".
Disassemble
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Detach both tapered roller bearing inner races (3) with KM-161-B
(1), KM-161-3 and KM-161-4 (2), if necessary unscrew remover hooks
from counterhold and install individually on bearing.
If still present, disassemble (destroy) and remove speedometer
gear (driving) – will not be later replaced.
Remove drive gear (4) from differential: Mark bearing ring
position in relation to differential (arrow).
Loosen retaining plates (5) with screwdriver – remove 8
fastening bolts.
Remove drive gear from differential – if necessary use
plastic hammer.
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Remove
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Drive out both axle shaft seal rings from inside transmission or
converter housing using screwdriver. Press tapered roller bearing
outer race with KM-697 (2) and KM-711-3 (1) out of transmission
housing – ensure that transmission housing lies flush under
the press. Spacer (selective) (3) – remove arranged behind
outer race of tapered roller bearing (4).
Press tapered roller bearing outer race with KM-697 (5)
converter housing – ensure that converter housing lies flush
under the press. Remove friction washer (6) – arranged behind
tapered roller bearing outer race (7).
Caution
Do not confuse spacer (transmission housing side) and friction
washer (converter housing side). If using new bearings, always use
the thinnest spacer from "Service" department.
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Assemble
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Press spacer (selectable) and tapered roller bearing outer race
into transmission housing with KM-372-2 (1) – use KM-554 (3)
with KM-710 (2) as counterhold.
Press in thrust washer and tapered roller bearing outer race
with KM-523-4 (6), KM-514 (5) and KM-711-3 (4) – ensure that
converter housing lies flush under the press.
Note marks made on removal (9). Drive gear (driven) (8) to
differential housing: Heat in fluid on hot plate to approx. 100
°C. Attach drive gear (driven) with new fastening bolts (x8)
and new retaining plates (7) to differential housing and secure
– tightening torque 100 Nm / 74 lbf. ft.
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Install
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Press on tapered roller bearing inner races – with KM-514
(2) and KM-567-2 (1).
Caution
Tapered roller bearing inner races have different strengths. The
thinner bearing is for installation on the differential housing
side, the thicker bearing for installation on the drive gear
side.
Install
Insert differential into transmission housing in order to adjust
tapered roller bearing. Attach converter housing and fasten bolts
(15 units) – tightening torque 25 Nm / 18 lbf. ft.
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Measure
Measure starting torque of differential without gear set with
KM-6037 (1) and MKM-536-A (2).
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Measurement value:
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New bearing
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0.8 to 1.4 Nm / 0.6 to 1 lbf. ft.
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Run-in bearing
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0.4 to 0.7 Nm / 0.3 to 0.5 lbf. ft.
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 Adjust
Adjust starting torque by installing suitable spacers from
"Service" department. Installation of the spacer washer is carried
out below the outer racer of the tapered roller bearing in the
transmission housing. In order to do so remove converter housing,
differential and tapered roller bearing (only if adjustment is
necessary).
Install
Install differential – see operation "Differential, Remove
and Install (AF 17)".
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