AWD

Repair instructions
The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also naturally apply when carrying out vehicle repairs.

Special tools
A list of the special tools are listed in folder. "Workshop equipment and tools" or "Special tools".

Transmission
^ When replacing the rear final drive the oil level in rear final drive must be checked and, if necessary, corrected

^ When assembling mounting brackets as well as waxed components clean contact surfaces. The contact surfaces must be free of wax and grease.

Gaskets, sealing rings
^ Replace O-rings.
^ Radial shaft oil seals.





Before installing:
Lightly oil outer circumference and pack space between sealing lips arrow- half-full with sealing grease G 052 128 Al.

After installation:
Check gear oil in rear final drive, if necessary top up to lower edge of oil filler hole.

Locking elements
^ Replace circlips.
^ Do not over-stretch circlips.
^ Circlips must be properly seated in the base of the groove.





^ Replace spring pins.
Installation position: Slot longitudinal to line of force.

Nuts, bolts
^ Nuts and bolts which secure covers and housings should be slackened and tightened diagonally.
^ Parts which are particularly sensitive must not be tilted, loosen or tighten diagonally in stages.
^ The tightening torques stated apply to non-oiled nuts and bolts.
^ Replace self-locking bolts and nuts.
^ Ensure with all screw connections that contact surfaces as well as bolts and nuts are only waxed after assembly, if necessary.

Bearings
^ Attach the needle bearing with the written side (greater plate thickness) to the installing tool.
^ Install new taper roller bearings in delivery condition and do not oil additionally.
^ Always replace the taper roller bearings on one shaft together and use new bearings from a single manufacturer.
^ Heat inner races to approx. 100° C before installing.
^ Do not interchange the outer or inner races of bearings of the same size. The bearings are paired.

Adjustment shims
^ Check thickness of shims by measuring at several points with a micrometer. Different tolerances make it possible to obtain exact shim thickness required.
^ Check for burrs and damage.
^ Install only adjustment shims which are in perfect condition.