Removing and Installing/Replacing Front Axle Differential

Removing and Installing/Replacing Front Axle Differential

Note:
Front axle support must be lowered before front axle differential can be removed.
There is no need to perform a front axle alignment check.
After completing work, top up front axle differential fluid level.

Caution:
Use only the approved gear oil in this front axle differential.
Failure to comply with this requirement will result in serious damage to the differential!

Disconnect battery, grounding strap to body.
Remove heater bulkhead.





Lift engine hood into assembly position.

Note:
The following work must be carried out with a second person assisting. Work instruction applies to left and right sides.
Gently raise retaining clip and simultaneously push upwards.
Hold engine hood, unhook damper on hood. Open engine hood fully and reattach damper with special tool 51 2 170 to hood.





Remove cover for fuel injectors.

Remove upper section of suction filter housing with mass air flow sensor.





Fit special tool 00 0 200 to special tool 00 0 201/202/204/208 and attach.
Attach special tool 11 0 020 as shown in illustration to special tool 00 0 200.





Secure special tool 11 0 020 to front and rear engine suspension eyes.

Caution:
Make sure no lines or cables on rear side of engine are damaged by chain.

The supports (1) of special tool 00 0 208 must make contact with the screws on the side walls.





Tighten the screws (1 and 2).





Unfasten top left and right nuts on engine mount.





Raise engine with special tool 00 0 200 approx. 5 mm.

Caution:
The section "Removing and installing reinforcement plate" contains important installation instructions, refer to Steering and Suspension, Suspension, Cross-Member.

Remove reinforcement plate.
Remove front splash guard.

Remove front propeller shaft.
Unfasten steering spindle from steering gear. This operation is described "Removing and installing power steering", refer to Steering and Suspension, Steering, Power Steering.





Note:
Output shaft is not pressed out of drive flange.
Output shaft (1) and swivel bearing (2) remain together as a unit for removal and installation.

Remove left and right swivel bearings, refer to Steering and Suspension, Steering, Steering Knuckle.
Remove output shafts, refer to Drive Axles, Bearings and Joints, Axle Shaft Assembly.





As shown in illustration, support front axle support with special tool 00 2 030 in conjunction with special tool 31 2 220 and a block of wood.





Detach front axle support from engine carrier. Screw in special tool 31 1 150 in place of original screws approx. 20 mm and lower front axle support.

Note:
The screws of the E38 front axle support (Part No. 9 900 223) can be used in place of special tool 31 1 150.

Tightening torque and installation instructions for front axle support. Specifications

Remove left engine mount.





Pull off vent hose.





Release screws (1) and remove front axle differential.
Tightening torque:
- Front axle final drive to engine oil pan 45 Nm

Carefully feed out front axle differential towards bottom.

Caution:
If an assembly ring is already fitted, it must be removed.
The task must be carried out before the new sealing ring is inserted with the assembly ring.

Installation:





Insert new sealing ring (1) groove and apply anti-friction agent.

Installation:





Push on assembly ring (1) up to sealing ring.

Installation:





The assembly ring (1) ensures that the sealing ring (2) is not damaged when the front axle differential is installed on the engine oil sump.
When the front axle differential is installed on the oil sump, the assembly ring (1) is forced over the sealing ring (2) and remains fitted.





Open filler plug (1) and check fluid level in front axle differential.
Fluid level to lower edge of filler plug.
Tightening torque:
- Filler/drain plug 65 Nm

Note:
Replace sealing ring.