AR35.30-T-0676AA | Disassembling and assembling portal housing with portal axle final drive | 27.2.12 |
REAR AXLE 748.120 /121 /122 /123 /124 /125 /126 /134 /135
T35.10-0026-01
1 Portal housing
2 Rpm sensor
Modification notes
| Disassemble | ||
1 | Detach rpm sensor (2) from portal housing (1) | To do this, loosen bolt and carefully pull out rpm sensor (2). | |
2 | Remove portal housing (1) with portal axle final drive | ||
3 | Fit support to portal housing (1) and attach to maintenance unit | Secure portal housing (1) to prevent it from falling down. Align end face on rear axle bridge side of portal housing (1) upwards. | |
Maintenance unit for rear axle portal housing, Zahnradfabrik Passau GmbH D-94034 Passau | |||
Support for rear axle portal housing, Zahnradfabrik Passau GmbH D-94034 Passau | |||
Ring bolt assortment, Zahnradfabrik Passau GmbH D-94034 Passau | |||
Stop chain, 3-train, Zahnradfabrik Passau GmbH D-94034 Passau | |||
4 | Remove input shaft of portal axle final drive | ||
5 | Remove driven gear of portal axle final drive | ||
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6 | Remove outer race of tapered roller bearing output gear from the brake carrier | Remove existing shim. | |
Slide hammer puller | |||
7 | Disassemble output gear of portal axle drive | Only required if the output gear of the portal axle drive or the tapered roller bearings of the output gear of the portal axle drive are replaced | |
8 | Drive the outer race of the tapered roller bearing of the output gear out of the portal housing (1) | Drive out the outer race of the tapered roller bearing output gear through the portal housing (1) from above using a suitable drift. | |
9 | Remove drive gear of portal axle drive from the portal housing (1 | ||
10 | Swing portal housing (1) | The alignment of the portal housing (1) is with the end face of the rear axle bridge side upwards. | |
11 | Remove outer race of the tapered roller bearing of differential from the portal housing (1) | Remove existing shim for the preload of the bearing from the differential. | |
Pry bar | |||
12 | Remove stud bolts from the portal housing (1) | ||
13 | Remove intermediate gears of portal axle drive from the portal housing (1) | When removing the intermediate gears identify the assignment and installation position of the separate parts. | |
14 | Disassemble intermediate gears of portal axle final drive | Only carry out if the intermediate gears or tapered roller bearings of the intermediate gears have been replaced. If intermediate gears which have already run are used again, identify the assignment and installation position of the separate parts. | |
15 | Clean all parts and check for wear. | Replace worn or damaged parts. | |
| Assemble | ||
16 | Screw stud bolts into the portal housing (1) | Cover stud bolts with locking agent. | |
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17 | Rotate portal housing (1) through 180° | Align portal housing (1) with the end face on the rear wheel hub side upwards. | |
18 | Install drive gear of portal axle drive in the portal housing (1) | If no disk springs are fitted in the drive gear bearing the portal housing (1) must be swiveled through 180° before installing the intermediate gears and the axial play of the drive gear measured: | |
Measuring axial play of drive gear of portal axle final drive If the measured axial play is not within the permissible tolerance, the shim on the upper axial bearing of the drive gear must be corrected. | |||
19 | Rotate portal housing (1) through 180° | If required | |
20 | Assemble intermediate gear of portal axle final drive | Only carry out if the intermediate gears or tapered roller bearings of the intermediate gears have been replaced. When reusing intermediate gears which have already run the assignment and installation position of the separate parts is to be observed. | |
21 | Measuring axial play of intermediate gear of portal axle final drive | When using the shim found beforehand during disassembly in our experience the required adjustment values result, however a check is imperative. Correct the axial play if necessary by installing the corresponding shim. | |
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Plug gauge, Zahnradfabrik Passau GmbH D-94034 Passau | |||
Pry bar | |||
Workshop press gotis://G_58.2_01.0 | |||
22 | Install intermediate gears of the portal axle drive in the portal housing (1) | When reusing intermediate gears which have already run the assignment and installation position of the separate parts is to be observed. | |
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Adjuster screws, Zahnradfabrik Passau GmbH D-94034 Passau | |||
23 | Install axle shaft in portal axle drive | Only perform this step on the version with locating pins between input shaft and drive gear. | |
24 | Assemble driven gear of portal axle final drive | Only required if the output gear of the portal axle drive or the tapered roller bearing of the output gear of the portal axle drive have been replaced. | |
Heating plate | |||
Workshop press gotis://G_58.2_01.0 | |||
25 | Install outer race of tapered roller bearing of output gear in the portal housing (1) | ||
26 | Fix the drive gear of the portal axle drive in position by means of inserting the axle shaft of the portal axle drive | Only perform this step on the version without locating pins between input shaft and drive gear. | |
27 | Push the output gear of the portal axle drive in the portal housing (1) | The pulse plate faces towards the center of the axle. | |
28 | Pull input shaft of portal axle final drive out of drive gear | Only perform this step on the version without locating pins between input shaft and drive gear. | |
29 | Install outer race of the tapered roller bearing of the output gear in the brake carrier | Install shim. When using the shim found beforehand during disassembly in our experience the required adjustment values result, however a check is imperative. Correct the axial play if necessary by installing the corresponding shim. | |
30 | Install brake carrier provisionally | Do not install the O-ring yet. First only fasten the brake carrier with six bolts. Do not secure the bolts with adhesive yet. Crank the output gear several times in both directions and release the load on the bearing by means of light blows with a plastic mallet on the brake carrier | |
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31 | Measure axial play of driven gear of portal axle final drive | If the measured axial play is not within the permissible tolerance, make a correction to the shim under the outer race of the tapered roller bearing of the output gear of the portal axle drive in the brake carrier. | |
32 | Detach brake carrier from portal housing (1) | ||
33 | Install brake carrier on portal housing (1) | Replace O-ring. | |
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34 | Rotate portal housing (1) through 180° | Align portal housing (1) with the end face on the rear axle housing side upwards. | |
35 | Determine the thickness of the adjusting washer in the portal housing (1) for adjusting the rolling moment of the differential bearing | ||
36 | Install outer race of tapered roller bearing of differential bearing in the portal housing (1) | Install shim for rolling moment 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. | |
37 | Install input shaft of portal axle final drive | Only perform this step on the version without locating pins between input shaft and drive gear. | |
38 | Detach portal housing (1) from support and maintenance unit | Secure portal housing (1) to prevent it from falling down. | |
Maintenance unit for rear axle portal housing, Zahnradfabrik Passau GmbH D-94034 Passau | |||
Support for rear axle portal housing, Zahnradfabrik Passau GmbH D-94034 Passau | |||
Ring bolt assortment, Zahnradfabrik Passau GmbH D-94034 Passau | |||
Stop chain, 3-train, Zahnradfabrik Passau GmbH D-94034 Passau | |||
39 | Install portal housing (1) with portal axle final drive | ||
40 | Install rpm sensor (2) on portal housing (1) | | |
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Inspection data of rear axle final drive
Number | Designation | Rear axle | Rear axles | ||
BE35.30-N-1002-01L | Axial play of intermediate gear of portal axle final drive | mm | 0.05...0.08 | 0.01...0.05 | |
Rear axle carrier
Number | Designation | Rear axles | ||
BA35.10-N-1002-01B | Bolt, brake carrier to portal housing | Cylinder head bolt | Nm | 200 |
Torx screw | Nm | 185 | ||
BA35.10-N-1003-01B | Pan head bolt, rpm sensor to portal housing | Nm | 9...10 | |
Axle housing
Rear axle drive
Number | Designation | Rear axles | |
BA35.30-N-1001-02H | Bolt, intermediate gear bearing pin to portal housing | Nm | 185 |
000 589 64 21 00
Dial indicator
Torque wrench
Torque wrench
Torque wrench
000 589 39 21 00
001 589 53 21 00
001 589 67 21 00
363 589 02 21 00
Dial indicator holder
Torque wrench
001 589 75 21 00
Repair materials
Number | Designation | Order number |
BR00.45-Z-1073-01A | Drei Bond silicone 1207 | Drei Bond GmbH |
BR00.45-Z-1133-02A | Loctite 243 | A 613 989 09 71 |
BR00.45-Z-1059-02A | Loctite 262 | Henkel Loctite Deutschland GmbH |
BR00.45-Z-1018-06A | MB multipurpose grease | - |