Removal and Replacement

Removing and installing front final drive








Preliminary work

Danger
Vehicle raised incorrectly.
Danger of fatal injury or material damage should the vehicle fall down.

- Raise the vehicle at the prescribed jacking points.

1. Jack and raise the vehicle at the prescribed jacking points.
2. Remove underbody panelling.
3. Remove the cardan shaft.

Removing front final drive

1. Remove front diagonal braces.





Diagonal braces

2. Remove front tank covering.





Removing front tank covering

Loosen retaining straps by unscrewing the screws -arrows-.

3. Remove drive shafts on the transmission side.
3.1. Counter using special tool adapter plate 9510/1 (-1-).





Retaining tool for drive-shaft bolts

3.2. Unscrew the six bolts between the drive shaft and transmission flange.





Drive shaft

Information
Protect drive shafts against mechanical damage (e.g. with a rubber hose that has been cut open).

4. Place transmission jack under the final drive and secure with a retaining strap.
5. Remove support for final drive.
5.1. Disengage pipe holder from lines and remove it.

Remove the pipe holder -1- by pulling off the cable plug -2- and pulling off the grab handles -arrows- on the coolant pipes.





Removing pipe holder

5.2. Unscrew screws securing support for final drive -A-.





Screws securing support for final drive

Never loosen screw on transmission mount -B-.

6. Remove front carrier.

Loosen nuts -B- for front carrier -A- and unscrew the studs -C-.





Final drive mount

7. Remove the final drive.
7.1. Disconnect electric plug -arrow-.





Disconnecting electric plug

7.2. Carefully lower the final drive out. Avoid damaging the coolant pipes when doing so.

Installing front final drive

1. Install front final drive.

Carefully guide the front final drive into position from below. Avoid damaging the coolant pipes when doing so.

2. Remove front carrier.
2.1. Screw studs -C- through the transmission support -A- and into the front-axle cross member.





Final drive mount

- Tightening torque: 20 Nm (15 ftlb.)

2.2. Screw nuts -B- onto studs and tighten them.

- Tightening torque: 65 Nm (48 ftlb.)

3. Fit support for final drive.
3.1. Engage pipe holder on lines.





Installing pipe holder

Press on grab handles -arrows- on the coolant pipes and connect cable plug -2-. Slide the pipe holder -1- back until it engages on the support for final drive.

3.2. Secure support for final drive.





Support for final drive

Screw in and tighten screws -arrows-.

- Tightening torque: 65 Nm (48 ftlb.)

4. Remove transmission jack.
5. Fit drive shafts on the transmission side.
5.1. Counter using special tool adapter plate 9510/1 (-1-).





Retaining tool for drive-shaft bolts

5.2. Screw in and tighten the six bolts between the drive shaft and transmission flange.

- Tightening torque: 39 Nm (29 ftlb.)





Drive shaft

6. Install tank covering at the front.





Installing tank covering

Fit tank covering and secure with retaining straps by screwing in and tightening screws -arrows-.





7. Install front diagonal braces.





Installing diagonal braces

Fit diagonal braces and make sure the arrows on the diagonal braces are pointing forward. Then screw in and tighten screws -arrows-.

- Tightening torque: 100 Nm (74 ftlb.)

Subsequent work

1. Install cardan shaft.
2. Check oil for front final drive and top up if necessary.
3. Install underbody panelling.
4. Lower the vehicle.