Differential Lock: Service and Repair

Removing and installing electromagnetic clutch








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.
4. Drain clutch fluid for front final drive.
5. Remove front final drive.
6. Remove support for front final drive.

Removing electromagnetic clutch

1. Clamp the final drive in a vice.

Retainer plate 9756 must be secured on the transmission housing and clamped in a vice.





Suspending transmission

2. Unpin electric plug.
2.1. Pull electric plug off the housing.





Electric plug

2.2. Open secondary lock in the plug.





Opening secondary lock

2.3. Loosen the two pins in the plug and pull cable and pins out of the plug using the press-out tool Nr.154 Pos.1.





Loosening pins

3. Remove long-neck pipe.
3.1. Disengage the vent line by loosening it at the retaining clips -arrows- and removing it.





Vent line

3.2. Remove screws -arrows-.





Screws

Detach long-neck pipe from the housing using a rubber hammer if necessary. To detach the long-neck pipe, tilt it downwards and guide it out towards the rear.

4. Remove electromagnetic clutch.
4.1. Clamp the long-neck pipe in a vice and unscrew the screws between the clutch and long-neck pipe.





Long-neck pipe

4.2. Remove clutch from long-neck pipe.

Installing electromagnetic clutch

Information
Check all O-rings on the clutch for signs of damage before fitting it.

Coat all O-rings on the clutch with clutch fluid before fitting it.

1. Install electromagnetic clutch
1.1. Insert screws (M8 x 100 mm) -arrow- for guiding the clutch through the openings in the long-neck pipe and screw them (1 to 2 turns) into the thread on the clutch.





Installing clutch

1.2. Slide electric cable for clutch through the opening in the long-neck pipe.
1.3. Slide the clutch as far as it will go into the long-neck pipe, making sure that the teeth are positioned correctly.
1.4. Remove screws (M8 x 100 mm) and screw in original screws.

-> Tightening torque: 10 Nm (7.5 ftlb.)

2. Install long-neck pipe.
2.1. Insert long-neck pipe and clutch into the housing. The twist lock must be positioned correctly with respect to the retaining lug -arrow-.





Fitting long-neck pipe

2.2. Screw in screws -arrows- and tighten them crosswise in several stages.





Screws

-> Tightening torque: 23 Nm (17 ftlb.)

2.3. Engage vent line.





Vent line

Secure the vent line at the retaining clips -arrows-.

3. Pin in electric plug.
3.1. Insert both pins into the electric plug until they engage.
3.2. Close secondary lock in the plug.





Closing secondary lock

3.3. Connect electric plug to the housing.





Electric plug

4. Remove final drive from the vice and take off the retainer plate.

Unscrew screws for securing the retainer plate 9756 to the transmission housing.

Subsequent work

1. Install support for front final drive.
2. Install front final drive.
3. Fill in clutch fluid for front final drive.
4. Install the cardan shaft.
5. Install underbody panelling.
6. Lower the vehicle.