33 10 010 Removing And Installing/Replacing Rear Differential

33 10 010 Removing And Installing/Replacing Rear Differential

Special tools required:







WARNING:
Danger of injury.
Rear axle final drive must be lashed with tensioning strap 33 5 206 to prevent it falling out when the output shafts are forced off.







IMPORTANT:
When removing/re-installing the rear axle final drive, both shaft seals for the drive flange and the circlip on both output shafts must be replaced.
After completing repair work, check gearbox oil level.







Necessary preliminary tasks:
- Remove propeller shaft.
- Deactivate and drain air spring/suspension system







IMPORTANT:
The following jobs must be carried out in the specified sequence.







Release bolt (1) on left shock absorber.
Remove shock absorber from pivot arm.
Tightening torque 33 52 4AZ.







Special tools 33 5 120 and 33 5 125 must be inserted in all-round slot (1) on output shaft.







Use special tool 33 5 120 to press (in jolts) left output shaft by approx. 5 cm out of the rear axle final drive unit. The thrust piece of the bolt 33 5 122 positioned against the rear axle final drive unit (see arrow).







Position special tool 33 5 200 on workshop jack.
Support rear axle final drive 33 5 200 with special tool.
Lash rear axle final drive with tensioning strap 33 5 206 to special tool 33 5 200.

IMPORTANT: Tensioning strap 33 5 206 must be pass through between output shafts and rear axle final drive cover.







Release screws (1).

Installation note:
Adhere to the installation sequence at the end of the document in order to prevent distortion of the rear axle final drive during installation and thereby avoid potential complaints about noise.







Release nut and remove bolt (1).

Installation note:
Adhere to the installation sequence at the end of the document in order to prevent distortion of the rear axle final drive during installation and thereby avoid potential complaints about noise.







IMPORTANT:
Risk of damage.
Output shafts must not under any circumstances rest on swinging arms.

Secure special tool 31 5 220 with wheel studs to right drive flange.
Press right-hand wheel carrier max. approx. 10 cm upwards.







Lower rear axle final drive with special tool 33 5 200.

IMPORTANT:
Risk of damage.
Output shafts must under no circumstances rest on pivot arms.







Press front of final drive unit to the right.
Feed out left output shaft forwards and tie up.
Swing rear axle final drive towards left side.







Use special tool 33 5 120 to press (in jolts) right output shaft out of the rear axle final drive unit. Here, thrust piece of bolt 33 5 122 must rest on rear axle final drive.

Feed right output shaft out of rear axle final drive and tie up.
Remove rear axle final drive.







Installation:

IMPORTANT:
Check dust plate (1) for damage, renew if necessary.
Replace circlip (2).
Coat highlighted contact surface (3) of output shaft with approved final drive oil.
High installation forces indicate that the output shaft spline teeth are damaged or deformed.
Check splines and replaced parts if damaged.







Insert right output shaft into rear axle final drive unit.
Pull out assembly protection ring at lug (1) until one of the two predetermined breaking points gives.







IMPORTANT: In order to ensure correct locking of the output shaft in the rear axle final drive, make sure when driving in the output shaft that the tensioning strap 33 5 206 is not located between the rear axle final drive and the dust plate.

Drive output shaft with special tool 33 5 125 and a rubber mallet into rear axle final drive.







Press front of final drive unit to the right.
Working from the front, fit left output shaft into rear axle final drive unit.
Pull out assembly protection ring at lug until one of the two predetermined rupture points gives.
Drive output shaft with special tool 33 5 125 and a rubber mallet into rear axle final drive.







Tightening sequence:
1. Press rear axle final drive upward with workshop jack and special tool 33 5 200.
2. Insert screws (1) (do not tighten).
3. Insert bolt from rear and replace nut (2) (do not tighten down).
4. Release tensioning strap and lower special tool 33 5 200 and move away.
5. Tighten down screws (1).
Tightening torque 33 17 1AZ.

6. Tighten nut (2).
Tightening torque 33 17 2AZ.







After installation:
- Activate and fill air spring system
- Check final drive oil level, correct if necessary.

Replacement:
- Modify three-hole flange.