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Differential, Overhaul
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Disassemble
Remove differential – see operation "Rear Differential,
Disassemble". Clamp differential in vice. Remove tapered roller
bearing using KM-161-B (2) in conjunction with KM-621-18 (1). Apply
remover hook of KM-161-B (2) in recesses (arrows). Unscrew
fastening bolts (3) of ring gear. Remove ring gear from
differential with soft metal drift (4). Drive out differential
shaft from plane side (arrow) with suitable remover (5). Lever
retaining ring (6) from differential shaft. Clamp KM-621-25 (7) and
place ring gear side of differential on special service tool.
Insert counterpart of KM-621-25 (7) in differential from above.
Counterhold differential with KM-160 (8) and unscrew differential
pinion gears by turning KM-621-25 (7).
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 Clean
Clean all components that are going to be reused.
Inspect
Visually inspect all components for wear and damage.
Assemble
Place housing of differential on Tool KM-621-25 (1) clamped in
vice with ring gear side downwards.
Install new retaining ring (2) in differential housing.
Place one belleville spring (3) and one shim (4) on each drive
shaft ring gear. The difference in thickness between the two shims
must not exceed 0.1 mm.
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Place drive shaft pinion gears with shims and belleville springs
in differential housing on KM-621-25. Engage differential pinion
gears in splines of drive shaft pinion gears and align so that they
are exactly opposite each other. Before screwing in differential
pinion gears, move ball washers forwards in screw-in direction and
guide into their seats, so that they do not get tilted on the
differential housing.
Counterhold differential with KM-160 (2) and screw in
differential pinion gears by turning KM-621-25 (1).
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After screwing in differential pinion gears, drive KM-621-26
into the differential housing with the point towards the retaining
ring side of the differential housing using a plastic hammer,
aligning hole patterns of the washer and differential pinion gears
to the housing if necessary.
Caution
Drive in KM-621-26 (3) with a plastic hammer only to avoid
formation of burrs.
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Measure
Using torque wrench and KM-621-25 (1), measure slip torque of
differential. If the measured torque is too low or high, install a
thicker or thinner shim under the axle shaft pinion gear. To do
this, disassemble the differential again and reassemble as
described above with the new shims. Ensure that the difference in
thickness between the shims under the axle shaft pinion gears does
not exceed 0.1 mm.
Torque
Permissible torque: 15 to 30 Nm / 11 to 22 lbf. ft.
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Assemble
Push KM-621-26 through differential housing with differential
shaft, ensuring correct positioning of the shaft – groove to
retaining ring. When the differential shaft projects no more than
approx. 1 cm from differential housing, hold KM-621-26 by hand and
drive differential shaft rapidly over retaining ring, so that it
engages in the groove of the differential shaft.
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Place ring gear on a heating plate and heat to approx. 100
°C. To determine temperature, use thermochrome pencils or
suitable temperature gauge. After attaining temperature, place ring
gear on differential housing, install fastening bolts and tighten
in order shown.
Torque
Ring gear to differential – 115 Nm / 85 lbf. ft.
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Assemble
Press tapered roller bearing onto differential housing with
KM-273 (1).
Install differential – see operation "Rear Differential,
Assemble".
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