Remove/install crown wheel with differential

AR35.30-T-0464AA

Remove/install crown wheel with differential

4.4.07

27.6.05

Modified measuring cover incorporated

Steps 12, 13, 14, 15

AR35.30-T-4815-11AA

AR35.31-T-0550-25AA



Removing

1

Drain oil out of the rear axle bracket and both portal axle drives



Rear axle - oil change

AP35.00-T-3501AA

2

Remove rear axle.

 Secure the rear axle to prevent it from tilting.

AR35.10-T-0010AA

3

Detach portal housing from rear axle housing

 Secure portal housing to prevent it from falling down.

AR35.30-T-0675AA

4

Remove ring gear with differential (1) from rear axle housing

5

Remove outer race of tapered roller bearing of differential bearing from the rear axle housing

 Remove existing shim.

AR35.31-T-0550-09AA

6

Remove outer race of tapered roller bearing of differential bearing from the portal housing

 Remove existing shim.

AR35.30-T-0676-08AA

7

Clean all parts and check for damage and wear

 Damaged or worn parts must be replaced subject to a separate repair order.

If the drive pinion gear or ring gear are damaged then both parts must be replaced together (ring gear set): 

Disassemble/assemble ring gear with differential

AR35.30-T-0462AA

Remove/install drive pinion

AR35.30-T-0458AA



Install

8

Install outer race of tapered roller bearing of the differential bearing in the rear axle housing

 Place shim between the rear axle housing and outer race. When using the shim found beforehand during disassembly in our experience the required adjustment values result, however a check is imperative.

AR35.31-T-0550-21AA

Cap
Firma Zahnradfabrik Passau GmbH D-94034 Passau, Germany

Handle
Firma Zahnradfabrik Passau GmbH D-94034 Passau, Germany

9

Insert ring gear with differential (1) in the rear axle housing

10

Swing the rear axle housing into the vertical location

11

Place the outer race of the tapered roller bearing of the differential bearing on the tapered roller bearing

12

Install measuring cover on the rear axle housing

 Bring the measuring cover evenly into contact with the rear axle housing with 4 bolts and nuts. By tightening the correct preload of the differential bearing is achieved simultaneously. Crank the drive pinion gear several times in both directions for exact centering.



*BA35.31-N-1001-02A



*000589392100

Measuring cover,

Firma Zahnradfabrik Passau GmbH D-94034 Passau

13

Measure axial runout on ring gear

AR35.31-T-0550-48AA

14

Measure gear backlash between bevel gear and ring gear, correct if necessary

 If an adjustment of the gear backlash is necessary then procedures 8 to 13 should be repeated after replacing the shim between the rear axle housing and outer race.

AR35.31-T-0550-25AA

15

Determine the thickness of the shim in the portal housing for adjusting the preload of the differential bearing

 When using the shim found beforehand during disassembly in our experience the required adjustment values result, however a check is imperative.

AR35.30-T-4815-11AA

16

Install outer race of tapered roller bearing of the differential bearing in the portal housing

 Insert shim in the thickness determined in procedure 15 between the outer race and portal housing.

AR35.30-T-0676-08AA

17

Coat the drive flanks and overrun flanks of three ring gear teeth offset by 180° with Prussian blue

*BR00.45-Z-1002-07A

18

Insert differential with ring gear (1) in the rear axle housing

19

Provisionally install portal housing at rear axle housing

 Secure portal housing to prevent it from falling down. Only carry out the procedures which are necessary for installing the portal housing on the rear axle housing.

AR35.30-T-0675AA

20

Spin crown wheel several times in both directions by turning the drive flange

21

Determine total friction torque on drive flange

 The total friction torque must be approx. 2 to 3 Nm higher than the friction torque of the drive pinion bearing. An increase in rolling torque of 3 to 4 Nm is necessary when installing a completely preassembled portal drive:



Check rolling resistance of drive pinion gear

 Observe different friction torques of drive pinion bearing

AR35.30-T-0458-06AA

*BE35.30-N-1001-06B



*400589010700

22

Detach portal housing from rear axle housing

 Secure portal housing to prevent it from falling down.

AR35.30-T-0675AA

23

Remove differential with ring gear (1) from the rear axle housing



Checking

24

Check contact pattern of ring gear and drive pinion

 If the contact pattern is not OK the thickness of the shim between the outer race of the tapered roller bearing of the drive pinion bearing and the rear axle housing as well as the friction torque of the drive pinion bearing must be checked and changed if necessary:



AR35.30-T-0475-02AA

Remove/install drive pinion

 After this repeat procedures 14 to 24.

AR35.30-T-0458AA

25

Insert differential with ring gear (1) in the rear axle housing

26

Install portal housing on the rear axle housing

 Secure portal housing to prevent it from falling down.
Replace O-ring (2).

AR35.30-T-0675AA



*BA35.25-N-1004-01D



*000589392100

27

Install complete rear axle

AR35.10-T-0010AA

28

Fill rear axle housing and both portal axle final drives with oil



Rear axle - oil change

AP35.00-T-3501AA

Number

Designation

Rear axle
748.12/13
up to major assembly ident. no.
923127

Rear axle
748.12/13 as of major assembly ident. no.
923128

BE35.30-N-1001-06B

Friction torque of drive pinion bearing

Nm

4,5 (-3)

6 (-2/+4)

Number

Designation

Rear axles
748.12/13

BA35.25-N-1004-01D

Bolt, portal housing to axle housing

Cylinder head bolt

Nm

200

Torx screw

Nm

185

Number

Designation

Rear axles
748.12/13

BA35.31-N-1001-02A

Nut, measuring cover to rear axle housing

M141.5

Nm

200

Number

Designation

Order number

BR00.45-Z-1002-07A

Prussian Blue

-