AR33.30.P-0525P Remove/Install Front Axle Gear
Remove/install Front Axle Gear
DANGER:
- Lethal injuries are possible if vehicle slips off of lifting platform
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.
DANGER:
- Risk of explosion from hydrogen gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury with caustic burns to eyes and skin from battery electrolyte or from handling damaged lead-acid batteries
- No fire, sparks, open flames or smoking.
- Wear acid protection gloves, clothes and goggles. Pour battery electrolyte only into suitable and appropriately marked containers.
1 Disconnect ground cable of battery
2 Remove engine suction fan ducts in front of air cleaner
3 Detach air cleaner housing vertically upwards from the cylinder head covers.
NOTE:
- Installation: Moisten the retaining rubbers on the cylinder head covers and the sealing ring of the hot film mass air flow sensor in the air cleaner housing slightly with sliding compound.
- Liquid lubricant (Naphtolen H)
4 Put on engine support frame and lift engine a little
5 Detach return line of rack-and-pinion steering at front axle carrier (1) from above
NOTE: Four nuts between engine and radiator and one nut in front of right engine mount.
6 Raise vehicle
7 Remove front and rear engine compartment paneling from below
8 Detach return line of rack-and-pinion steering at front axle carrier (1) from below
NOTE: The nut is located in front of the steering coupling.
9 Remove right and left front axle shaft (60)
10 Remove intermediate shaft (34)
11 Detach torsion bar (77) on left and right from link rods (78)
12 Detach exhaust shielding plate (1k) above right rubber boot of rack-and-pinion steering
13 Detach retaining plate (1h) of rack-and-pinion steering
14 Pull rack-and-pinion steering backwards slightly and tie in place
15 Mark front axle gear propeller shaft (70) in relation to front axle gear flange
16 Detach front axle gear propeller shaft (70) from front axle gear flange
NOTE: Installation: Pay attention to marking.
17 Tie up front axle gear propeller shaft (70) to one side
18 Detach left and right engine mount at bottom from front axle carrier
19 Support front axle carrier (1)
20 Unscrew bolts (1f) of front axle carrier (1)
CAUTION: Installation: The bolts (1f) are self-tapping, so the following must be observe:
- Never recut the thread in the longitudinal member
- Install new bolts (1f)
- Only use original bolts (4 ea )
- Bolts (1f) must be screwed in perfectly straight
- Do not use an impact wrench
- Observe tightening torque
21 Lower front axle carrier (1)
CAUTION: Secure front axle carrier (1) against falling down
22 Remove exhaust shielding plate (69) for front axle gear propeller shaft (70)
23 Detach carrier for front axle gear (58)
24 Detach high-pressure line of rack-and-pinion steering at oil pan
25 Insert drift into radial sealing ring on outside right of front axle gear (50)
NOTE: To prevent transmission fluid from escaping from the hole during removal
26 Detach front axle gear (50) and remove
NOTE:
- Five bolts on left and two on right
- Ensure that transmission oil does not run out
27 Install in the reverse order
28 Checking front axle gear oil level and topping up if necessary
29 Perform basic programming
30 Read out fault memory with STAR DIAGNOSIS and erase if necessary