Disassembly/Assembly

COMPONENT NOTES AND INFORMATION

NOTE:
^ Refer to general repair instructions.
^ Replace both differential tapered roller bearings together as a set. Use the same make bearings if possible.

1 Final drive covers
- If these parts are replaced, adjustments are required, refer to Final Drive Assembly. Adjustments
2 Final drive housings
- If these parts are replaced, adjustments are required, refer to Final Drive Assembly. Adjustments
3 Tapered roller bearing outer race
- If these parts are replaced, adjustments are required, refer to Final Drive Assembly. Adjustments
- Removing, refer to Fig. 10, below.
- Installing, refer to Fig. 11, below.
4 Shim S2
- Note thickness
- List of adjustments, refer to Final Drive Assembly. Adjustments
5 Tapered roller bearing inner racer
- If these parts are replaced, adjustments are required, refer to Final Drive Assembly. Adjustments
- Pulling off, refer to Fig. 2, below.
- Pressing on, refer to Fig. 5, below.
6 Ring gear bolt
- Use only genuine bolts
- Tighten opposite bolts, then tighten to 90 Nm (66 ft lb) using diagonal pattern
7 Differential housings
- If these parts are replaced, adjustments are required, refer to Final Drive Assembly. Adjustments
8 Ring gear
- Matched with drive pinion (drive gear set)
- Removing, refer to Fig. 1, below.
- Installing, refer to Fig. 7, below.
9 Roll pin
- Drive in flush
10 Tapered roller bearing inner race
- If these parts are replaced, adjustments are required, refer to Final Drive Assembly. Adjustments
- Pulling off, refer to Fig. 3, below.
- Pressing on, refer to Fig. 4, below.
11 Tapered roller bearing outer race
- If these parts are replaced, adjustments are required, refer to Final Drive Assembly. Adjustments
- Removing, refer to Fig. 12, below.
- Installing, refer to Fig. 13, below.
12 Shim S1
- Note thickness
- List of adjustments, refer to Final Drive Assembly. Adjustments
13 Threaded connector
14 Large bevel gears
- Adjusting, refer to Figs. 8 and 9, below.
15 Small bevel gears
- Installing, refer to Fig. 6, below.
16 Shaft for bevel gears
- Drive out with drift
- Drive in carefully so that thrust washers are not damaged
- Secure with roll pin
17 Shim
- Re-determining thickness, refer to Figs. 8 and 9, below.
18 Thrust washer
- Check for cracks and surface damage
19 Shim for flanged shaft
- Re-determining thickness, refer to Flanged Shaft. Adjustments

PROCEDURE





Fig. 1 Driving ring gear off housing





Fig. 2 Pulling off inner race of large tapered roller bearing
- Before installing purling device, place thrust piece VW 40-105 onto differential housing.





Fig. 3 Pulling off inner race of small tapered roller bearing
- Before installing pulling device, place thrust piece VW 40-105 onto differential housing.





Fig. 4 Installing inner race for small tapered roller bearing
- Heat to approx. 100°C (212°F) before pressing on.





Fig. 5 Installing inner race for large tapered roller bearing
- Heat to approx. 100°C (212°F) before pressing on.





Fig. 6 Installing differential bevel gears
- Install large bevel gears with correct shims (see Figs. 8 and 9, below).
- Install small bevel gears offset 180° (stick on thrust washer with small amount of grease) and swivel in.
- Install threaded connector.
- Align thrust washers.
- Drive in shaft and secure.





Fig. 7 Installing ring gear
- Heat to approx. 100°C (212°F) before installing
- (-A-) Centering pins (shop-made)





Fig. 8 Adjusting differential bevel gears
- Install large bevel gears with the thinnest shims (0.5 mm).
- Install small bevel gears with thrust washers and press in shaft.
Do not now exchange bevel gears and thrust washers!
- Push small bevel gears to outside and check clearance of large bevel gears by hand (arrows).
- Adjust clearance by installing an appropriate shim so as to produce a clearance of max. 0.10 mm.

NOTE: The adjustment is also correct if no play is perceptible but the bevel gears can still be easily rotated without catching (see Fig. 9, below).

- The following shims are available:
Thickness: 0.5
Thickness: 0.6
Thickness: 0.7
Thickness: 0.8
Thickness: 0.9
Thickness: 1.0





Fig. 9 Rotating differential bevel gears





Fig. 10 Driving for tapered roller bearing outer race from final drive housing





Fig. 11 Driving tapered roller bearing outer race into final drive housing





Fig. 12 Driving tapered roller bearing outer race out of cover





Fig. 13 Driving tapered roller bearing outer race into cover