Disassembly/Assembly

Component Notes And Information

NOTE:
^ During service procedures, refer to the illustration above and the information below.
^ Heat tapered roller bearing inner race to 100°C (212°F) before pressing on.

1 Torque converter
- Is allocated to transmission according to engine version.
- Removing and installing, refer to Differential Assembly, Replacement
- As a replacement part differential is allocated according to transmission code letters refer to parts supplier
- On vehicles with diesel engine the Engine Speed (RPM) Sensor -G28- is installed in the top of the torque converter housing
2 Shim
- Determining thickness refer to adjusting differential. Adjustments
3 Circlip
- For securing speedometer drive gear
4 Speedometer drive gear
- Seat drive gear lugs into differential housing grooves, straight face outwards
5 Tapered roller bearing outer race
- Remove and install only when differential housing heated
- Pressing out refer to Fig. 1 below
- Pressing in refer to Fig. 2 below
6 Tapered roller bearing inner race
- Pulling off refer to Fig. 3 below
- Pressing on refer to Fig. 4 below
7 Bolt
- Tighten all bolts to 80 Nm (59 ft lb), + 90°
- Always replace
8 Differential housing
9 Final drive gear wheel
- Number of teeth refer to Code Letters, Application, Ratios, Equipment. Application and ID
- Install heated refer to, Fig. 5 below
10 Transmission housing
- Removing and installing refer to Differential Assembly, Replacement.
- As a replacement part housing is allocated according to transmission code letters, refer to parts supplier
- Before assembling transmission and torque converter housings together, coat sealing surfaces with AMV 188 200
11 Tapered roller bearing inner race
- Pulling off refer to Fig. 6 below
- Pressing into transmission housing refer to Fig. 7 below
12 Tapered roller bearing outer race
- Pulling off refer to Fig. 8 below
- Pressing into differential housing refer to Fig. 9 below
13 Large bevel gears
- Installing refer to Fig. 10 below
14 Small bevel gears
- Installing refer to Fig. 10 below
15 Shaft for bevel gears
- Drive out with a drift
- When driving in, do not damage one-piece thrust washer
16 Spring pin
- For securing shaft for bevel gears
- Removing and installing spring pin with circumferential groove refer to Fig. 11 below
17 One-piece thrust washer
- Place into differential housing before installing bevel gears

Procedures





Fig. 1 Tapered Roller Bearing Outer Race, Pressing Out

NOTE: Only press taper roller bearing outer race in when torque converter housing is heated.





Fig. 2 Tapered Roller Bearing Outer Race, Pressing Into Torque Converter Housing





Fig. 3 Tapered Roller Bearing Inner Race, Pressing Off
- Place press piece 40-105 on differential housing





Fig. 4 Tapered Roller Bearing Inner Race, Pressing On
- Press tapered roller bearing inner race onto stop on differential housing





Fig. 5 Heated Final Drive Gear Wheel, Installing
- Heat final drive gear wheel to approx. 100°C (212°F).
- Install final drive gear wheel over centralizing pins -A- (local manufacturer) on differential housing.

NOTE: Recess in gear wheel faces towards differential housing.





Fig. 6 Tapered Roller Bearing Inner Race, Removing
- A - Kukko 20-10 and Matra V 172 pulling hooks.
- Insert puller hooks into cut-outs in transmission housing.





Fig. 7 Tapered Roller Bearing Inner Race, Pressing Into Transmission Housing





Fig. 8 Tapered Roller Bearing Outer Race, Removing
- A - Kukko 20-10





Fig. 9 Tapered Roller Bearing Outer Ring, Pressing Into Differential Housing And Driving Fully Onto Stop With Drift





Fig. 10 Differential Bevel Gears, Installing
- Install one-piece thrust washer with gear oil.
- Install small bevel gears, drive in shaft and secure with spring pin.
- Install large bevel gears offset 180' and swivel in indirection of arrow.





Fig.11 Spring Pin With Circumferential Groove, Removing And Installing

Removing
- Drive out spring pin using a chisel.

Installing
- Drive in spring pin with groove facing outward.
- Drive in spring pin up to stop.