Overhaul of Standard Rear Differential

Disassembly

1 Clamp differential with self-made clamping device into vise.




2 Pull both tapered roller bearing inner races from differential housing with puller (1).




3 Knock clamping sleeve (28) for differential pinion shaft (36) out of differential housing (31) by means of a matching mandrel.

Complete differential of 1st version

26 Thrust washer
27 Side gear
28 Clamping sleeve
30 Ring gear
31 Differential housing
34 Differential pinion
35 Ball washer
36 Differential pinion shaft

4 Force out differential pinion shaft and remove differential pinions, side gears, thrust washers and ball washers.

Complete Differential Of 2nd Version:

Complete differential of 2nd version

12 Differential housing
14 Ball washer
15 Differential pinion
16 Differential pinion shaft
17 Side gear
18 Thrust washer
19 Clamping sleeve

5 Check individual parts for re-use. Renew all overheated or seized differential pinions, thrust washers and ball washers on principle.

6 Check bores in differential housing. Check fit and supporting surface for ring gear for radial and axial runout.

Assembly




7 Insert both assembly mandrels into bores of differential housing.

8 Place thrust washer on side gears.

9 Place both side gears with thrust washers on assembly mandrels in differential housing.





Attention! To facilitate assembly, the ball washers of the present version (B) of the differential are provided with a collar at OD and the differential pinions with a shoulder (arrow). Mount differential pinions and ball washers only in the combination shown in illustration.





10 Turn both differential pinions and ball washers together into differential housing by means of assembly mandrel (1).




11 Slip assembly mandrel (2) instead of differential bolt into differential housing to locate differential pinions and ball washers.





12 Check friction torque. Friction torque should amount to 30-90 Nm, at restraining points up to 100 Nm.


Note: Select thrust washers for side gears in such a manner that a given friction torque is available during assembly.





13 Knock in differential bolt while paying attention to bore for clamping sleeve.


14 Knock in new clamping sleeve.




15 Press inner races of tapered roller bearings on differential housing by means of assembly mandrel (1).
Assembly mandrel for:
small rear axle center piece: 115 589 04 61 00
large rear axle center piece: 116 589 08 61 00





Attention! To prevent damage to roller cage when pressing-on second inner race, use support (048) (for small rear axle center piece without lateral bearing caps only).