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Differential, Dismantle and Assemble (F18)
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1
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Axle shaft seal ring
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2
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Fastening bolt
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3
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Bearing flange
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4
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O-ring
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5
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Outer race of tapered roller bearing
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6
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Outer race of tapered roller bearing
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7
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Bearing ring
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8
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Lock tab
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9
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Spring washer
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10
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Fastening bolt
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11
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Axle shaft seal ring
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12
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O-ring
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13
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Fastening bolt
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Illustration, Differential (F18)
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14
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Differential cover
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15
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Gasket
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16
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Retaining pin
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17
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Inner race of tapered roller bearing
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18
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Differential housing
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19
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Differential housing axle
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20
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Axle shaft bevel gears
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21
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Thrust washer
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22
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Differential bevel gears
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23
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Thrust washer
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24
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Ring gear
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25
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Inner race of tapered roller bearing
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26
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Fastening bolt
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Note: Transmission
remains installed.
 Remove
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Remove axle shafts (1) – see operation "Axle Shafts,
Remove and Install" in group "E".
Remove end shield cover (2) – see operation "Gasket for
End Shield Cover, Replace – F13/F17/F17+/F18".
Remove end shield (3) from transmission housing – see
operation "Gasket for End Shield, Replace (F13/F17/F17+/F18)".
Remove differential (4) – see operation "Differential,
Remove and Install (F18)".
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Disassemble
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Remove seal rings from bearing ring (3) and transmission using
KM-454-2 (1) and KM-454-4 (2).
Only necessary for replacement: drive outer race for tapered
roller bearing out of bearing ring with KM-304 (4), KM-451 (5),
place KM-502-A underneath.
Drive outer race for tapered roller bearing out of bearing
flange with KM-304 (7), KM-451 (8), place KM-502-A underneath.
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Remove
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Remove drive gear fastening bolt (1) from differential housing
(2).
Knock drive gear from differential housing with brass drift.
Caution
Always replace drive gears (driving drive gear with main shaft)
in pairs. Note identification groove running around tip of
tooth.
Note: Following
illustrations show further dismantling without replacement of
tapered roller bearing inner races.
Remove
Drive out locking pin of bevel gear axle. Press bevel gear axle
out of differential housing.
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Remove
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Screw out differential bevel pinion with friction washer. Remove
axle drive bevel gear with friction washer.
Disassemble
Only necessary for replacement: pull off both tapered roller
bearing inner races with KM-161-B (1), KM-161-3 (2) and KM-161-4
(3).
Note: When re-using
the tapered roller bearing, the respective outer and inner races
must not be swapped over. For overhaul operations, the speedometer
gear (driving) should be destroyed, if still present. On assembly
it is not re-installed.
Inspect
Removed parts for wear, signs of scoring, damage, hairline
cracks; if necessary replace.
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Note: Lubricate
rotating parts on their bearing, running, seating, and pressure
surfaces using transmission fluid.
Assemble
Insert axle drive bevel gear with friction washer in
differential housing.
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Screw in differential bevel pinions with friction washer into
differential housing (1) and centre with KM-160-4 (2).
Pull out KM-160-4 and insert bevel gear shaft into differential
housing. Drive in locking pin and secure through centre
punching.
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 Adjust
Pre-tension of axle shaft bevel gears.
Measure breakaway torque for installation free of play (no
backlash) – KM-995-A, MKM-536-A. Nominal value: 8 to 15 Nm /
6 to 11 lbf. ft. For excessively high breakaway torques use thinner
adjusting washer. For excessively low breakaway torques use thicker
adjusting washers.
Available washer thicknesses: 0.82 mm, 0.88 mm, 0.94 mm.
After adjustment is completed: Drive in locking pin and secure
by centre punching at bore edge.
Install
Clamp differential housing in vice, KM-524-A.
Assemble
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Attach drive gear (1) with new fastening bolts to differential
housing – tightening torque 70 Nm / 52 lbf. ft. +
45°.
Note: Replace drive
gears only in pairs (driving and driven). Note identification
groove (arrows) running around tip of tooth.
Assemble
Press tapered roller bearing inner races (3) onto differential
housing (4) with KM-522 (2).
Install respective outer race for tapered roller bearing in
transmission or bearing ring – use KM-305 and KM-451. Stop
outer race for tapered roller bearing lightly in housing.
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Install
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Press respective outer race for tapered roller bearing into
bearing flange (3) or bearing ring to the stop, KM-305 (1) and
KM-451 (2).
Drive new axle shaft seal ring into bearing flange and bearing
ring with KM-519 – see operation "Axle Shaft Seal Ring,
Replace (F13/F17/F17+/F18)".
Install differential (4) – see operation "Differential,
Remove and Install (F18)".
Install end shield (5) – see operation "Gasket for End
Shield, Replace – F13/F17/F17+/F18".
Install end shield cover (6) – see operation "Gasket for
End Shield Cover, Replace (F13/F17/F17+/F18)".
Install axle shafts – see operation "Axle Shafts, Remove
and Install" in group "E".
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