Differential Assembly: Service and Repair

Removing Front Wheel Drive
1. Remove the cardan shaft, refer to Drive/Propeller Shaft.
2. Remove underbody cover (front).





3. Remove diagonal brace -A- and cover -B-.
4. Remove drive shafts at the transmission and protect the shafts against damage (use scrap pieces of hose with a diameter of 30 mm)

Note: To protect the coolant pipes against scratches when the final drive is removed or installed, it is advisable to protect the pipes with adhesive tape in the area of the final drive.

5. Place transmission jack under the transmission and secure with fixing strap.





6. Remove pipe holder and unscrew fastening screws/nuts for the rear transmission support.
A - Pipe holder
B - Transmission support
C - Screw

Note: Do not undo screw -C-.





7. Undo fastening nuts for front transmission support and unscrew the studs.
A - Transmission support
B - Hexagon nut
C - Stud
8. Carefully lower the transmission out. When doing so, avoid damaging the coolant pipes.

Installing The Front Wheel Drive
Install in reverse order, observing the following points:





1. Carefully lift in the transmission with a universal transmission jack. When doing so, do not damage the coolant pipes.
2. Push studs through the front transmission mounts and screw into the front-axle cross member.

Note: It the hexagon-head bolt (M10 x 90) was undone on the rear transmission support/transmission mount, it is essential to tighten the front transmission support first, then the rear transmission support and the M10 x 90 screw on the rear transmission mount last.

3. Fasten transmission mounts on the front-axle cross member and on the body.

Tightening torques
Location Thread Tightening Torque Nm (ft. lbs.)
Studs on front-axle
cross member M8 20 Nm (15 ft. lbs.)
Front transmission support
on transmission M10 65 Nm (48 ft. lbs.)
on front-axle crossmember M10 65 Nm (48 ft. lbs.)
Rear transmission support
on body M10 65 Nm (48 ft. lbs.)
on transmission mount M10 X 90 65 Nm (48 ft. lbs.)
Drive shafts on
front-axle final drive M8 39 Nm (29 ft. lbs.)
Diagonal braces on body
and front-axle crossmember M12 100 Nm (74 ft. lbs.)
Tank strap on body M8 x 40 23 Nm (17 ft. lbs.)
Pipe holder on
transmission support M6 7 Nm (5 ft. lbs.)