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Differential gear, dismantling and assembly

Differential gear, dismantling and assembly

Illustration, differential gear


1 Drive shaft sealing ring
2 Outer ring, taper roller bearing
3 Bearing ring
4 Locking plate
5 Spring ring
6 Bolt
7 Drive shaft sealing ring
8 Rubber O-ring
9 Bolt
10 Differential cover
11 Gasket
12 Circlips
13 Inner ring, taper roller bearing
14 Differential pinion shaft
15 Differential housing
16 Housing insert
17 Drive shaft pinions
18 Differential pinions
19 Drive gear
20 Inner ring, taper roller bearing
21 Outer ring, taper roller bearing
22 Bolt


To dismantle

Note

The gearbox remains in place.



1. Remove the drive shafts (1). See Drive shaft, removal and fitting F17


2. Remove the bearing housing cover (2) - see service procedure Bearing housing cover gasket, replacement F 17 .

3. Remove the differential gear (4). See Differential gear, removal and fitting, F 17 .

4. Remove the sealing ring from the bearing ring (3) and gearbox with 87 92 905 Fitting tool, needle bearing F17 or K-454-2 (1) and KM-454-4 (2).


5. Only necessary when changing the bearing in the bearing ring: Remove the outer taper roller bearing ring with KM-304 or 87 92 863 Fitting tool, differential bearing F17 (4) and KM-451 or 87 92 897 Fitting tool, gearcase bearing F17 (5).

6. Remove the outer taper roller bearing ring from the gearbox. Use KM-305 and KM-451 or 87 92 897 Fitting tool gearcase bearing F17 . Use KM-304 or 87 92 863 Fitting tool, differential bearing F17 and KM-451 or 87 92 897 Fitting tool, gearcase bearing F17 on a removed gearbox.

7. Only necessary on replacement: Pull out both the inner taper roller bearing rings (1) with KM-161-B or 87 92 343 Puller, differential bearing 5 (2), KM-161-3 (4) and KM-161-4 (3).


Note

When re-using taper roller bearings the inner and outer rings must not be interchanged.


8. During repairs, if a speedometer pinion (driving) (5) is fitted, it should be discarded. On re-assembly a new pinion should not be fitted.

9. Clamp the differential housing in a vice using protective vice-jaws. Remove the drive gear from the differential housing.

Note

Always replace both the final drive gears (1) (pinion and gear wheel) at the same time. Note the groove (arrowed) around the crown of the gear.


10. Only necessary on replacement: Remove the circlips (2) from the differential pinion shaft. Remove the differential pinion shaft.

11. Unscrew the drive shaft pinions and the differential pinions with KM-458-A. Remove the plastic sleeve.

12. Clean all the dismantled components and the gearcase.

Check all parts for wear, pitting or damage. Replace if necessary. Wet all bearings, contact surfaces and press-fit surfaces on the rotating parts with gearbox oil.


Assembly

Fit the housing insert into the differential housing.

Note


1. The edge of the insert (1) must locate in the drive axle pinion seat in the housing.


2. Locate/screw in the drive shaft pinions and differential pinions in the differential housing.

3. Clamp the differential housing together with KM-458-A (3) in a vice using protective vice-jaws.

4. Centralise the differential pinions with KM-456 (2).

5. Fit the differential pinion shaft (6) and lock with new circlips. (4 and 5).

6. Fit the drive gear (1) onto the differential housing with new bolts. Tightening torque 80 Nm.


Note

Always replace both the final drive gears (pinion and gear wheel) at the same time. Note the groove (arrowed) around the crown of the gear.


7. Press in the inner taper roller bearing rings (3) into the differential housing (4) with KM-453 (2).

8. Fit the outer taper roller bearing ring (2) in the gearbox and/or the bearing ring with KM-304 (1) and KM-451 (3).


9. Tap in the drive shaft seal in the bearing seat with KM-446. See service procedure "Drive shaft seal, replacement F 17".

10. Fit the differential gear (4). See Differential gear, removal and fitting, F17 .

11. Fit the bearing housing cover (6). See Bearing housing cover gasket, replacement F 17 .

12. Fit the drive shafts. See Drive shaft, removal and fitting F17