Differential Case: Service and Repair

Rear Axle Assembly Diameter 198 mm Without Side Bearing Caps:

REMOVAL
1. Raise and support vehicle, then drain rear axle oil

WARNING
^ Risk of fatal injury due to vehicle slipping off or tilting on the hoist
^ Align vehicle between the pillars of the hoist and position the four support plates at the hoist mounting points specified by the vehicle manufacturer

2. Detach rear axle shafts (37) from connection flange
- Move rear axle shaft so that it is almost horizontal, push together and remove from connecting flange downwards at an angle and tie securely to rear spring
3. Using assembly attachment tool No. 140 589 01 62 00, or equivalent, and a suitable lifting device, support rear axle center assembly (50)
4. Detach extension carrier (54a)
- To be able to remove the extension carrier, press the right hand hexagon bolt on the rear axle cross member back against the spare wheel recess
5. Detach end cover (54)





6. Using removing and installing tool No. 116 589 01 62 00, or equivalent, pull off locking ring (30)
- Discard locking ring
7. Pull out connecting flanges (33, 33a, 33b)
- Check contact surface for the radial seal ring on connecting flange, if severely scored, replace connecting flange





8. Using a suitable pry bar, press out radial seal rings (32, 32a, 70j)
9. Remove and discard rear axle breather (55)

INSTALLATION
- Install in reverse order, noting the following information:
- Replace axle to connecting flange self-locking bolts with internal serrations or hexagon socket bolts and washers.
- Lightly lubricate bolt thread and bolt head support.
- Replace self-locking nut (62b)
- Clean end cover sealing surface and coat with Hylomar sealing compound part No. 001 989 25 20, or equivalent.
- Replace end cover collared bolts (56b)
- Replace locking ring (30)





- Check and adjust connecting flange axial play as follows:
a. Check axial play between connecting flange (33a) and differential side gear (17), if necessary, fit a locking ring (30a) of greater or lesser thickness.
b. The axial play must be within the specified tolerance range of: 0.03-0.3mm
c. Spacers are available in the range of thicknesses 1.4 mm up to 2.7 mm, in stages of 0.05 mm.
- Coat outside diameter and sealing lip of sealing ring with universal hypoid gear oil SAE 85W90 or equivalent





- Using drift punch tool No. 140 589 10 15 00, or equivalent drive new seal into place
- Replace axle breather and tighten to: 30 Nm
- Tighten the following components as noted:
- Self-locking nut, rear extension carrier to rear axle carrier: 100 Nm
- Bolt, rear extension carrier to rear axle center assembly
Colored yellow: 80 Nm
Colored silver or blue: 70 Nm
- Self-locking bolt, rear axle shaft to connecting flange
10 mm bolt: 70 Nm
12 mm bolt: 100 Nm

NOTE: Thread and bolt head support lubricated)

- Collared bolts, end cover to rear axle center assembly: 50 Nm
- Fill rear axle center assembly with 1.2 liters of suitable differential fluid