Remove/install crown wheel with differential

AR35.30-B-0464G

Remove/install crown wheel with differential

04.08.2020

Rear axle

748.590/594 in model 934.2, 958.4

7

Safety lock

1

Differential assembly casing

8

Bolt (safety lock)

2

Threaded ring

9

Bolt (bearing cap)

3

Bearing cap

10

Sprocket

4

Threaded ring

11

Dial gauge

5

Taper roller bearing

12

Gauge holder

6

Bearing cap



Remove

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

1

Remove the bolt (8) and remove the safety lock (7)

2

Remove the threaded rings (2, 4) from the bearing caps (3, 6)


Immobilize the differential case, using a chisel to remove the threaded rings (2, 4).
This aims at avoiding damages to the tapered roller bearings (5) on the differential case (1).

 Claw wrench

*055589150700

 Claw wrench

*055589160700

3

Remove the bolts (9) and lift the bearing caps (3, 6)

4

Remove the crown gear (10) with the differential case



Check

5

Check the bevel gear (10) and the drive pinion for wear and damages

 If necessary, replace the bevel gear (10) and the pinion.

 Lifting device

*055589165900

6

Check the tapered roller bearings (5, )

If needed, replace the tapered roller bearings (5).

Detach tapered roller bearing from ring gear

AR35.30-B-4301-02GA

Attach tapered roller bearing to ring gear

AR35.30-B-4301-03RVI

Detach tapered roller bearings from differential case

AR35.30-B-4301-01GA

Assemble the tapered roller bearing in the differential case

AR35.30-B-4300-05GA



Install

7

Install the crown gear (10) with the differential set in differential set case (1)


When installing the bevel gear (10) with the differential set in the differential case (1), install the external tapered roller bearing caps (5) together with the differential set case.
This will cause the differential alignment and will make easier the assembly of the bearing caps (3, 6) avoiding damaging the tapered roller bearings (5).

 Oil the tapered roller bearing (5).

Lubricating oil for transfer case and drive axle, DB supply specification 6630.00 - SAE 85W90 and 90

*BR00.45-Z-1112-06A

 Lifting device

*055589165900

8

Install the bearing caps (3, 6) with the bolts (9)

 Tighten firmly the bolts (9) of the bearing caps (3, 6) without using a torque meter.

9

Install the threaded ring (4) beside the bevel gear (10)

 By installing the threaded ring (4), check if it is screwed in a free and easy way.

10

Install the threaded ring (2) beside the differential

 When installing the threaded ring (2) check if after screwed it is free and has easy handling condition.

11

Tighten the bolts (9) of the bearing caps up to the torque prescribed for the 1st stage

 After the tightening of the bearing caps (3, 6) bolts (9) up to the torque prescribed for the 1st stage, turn the differential case some times for the tapered roller bearings (5) to seat.

 Differential mounting bearing cap

*BA35.30-B-1004-03L

12

Adjust the play of the teeth flanks of the differential set

AR35.30-B-0475XD

 Claw wrench

*055589160700

 Claw wrench

*055589150700

 Dial gage

*001589532100

 Dial indicator holder

*363589022100

13

Adjust the pre-load of the tapered roller bearings (5)

AR35.30-B-4302-01XD

14

Tighten the bolts (9) of the bearing caps (3, 6) up to the torque prescribed for the 2nd stage

 Differential mounting bearing cap

*BA35.30-B-1004-03L

15

Install the threaded rings (2, 4) safety locks (7) and tighten the bolts (8) up to the prescribed torque

 Safety lock bolt to bearing cap

*BA35.30-B-1003-03L

 Central actuation with differential

Number

Designation

Rear axle 748.590/594

BA35.30-B-1003-03L

Safety lock bolt to bearing cap

M8

Nm

25

 Central actuation with differential

Number

Designation

Rear axle 748.590/594

BA35.30-B-1004-03L

Differential mounting bearing cap

M22x1.5

1st stage

Nm

200

2nd stage

° angular

90

Repair materials

Number

Designation

Order number

BR00.45-Z-1112-06A

Lubricating oil for transfer case and drive axle, DB supply specification 6630.00 - SAE 85W90 and 90

Use corresponding commercially available repair materials.