Remove and install drive pinion and ring gear with differential

AR35.30-D-4815H

Remove and install drive pinion and ring gear with differential

13.02.2020

Rear axle

741.412 in model 900.63

Rear axle

741.412/415 in model 906.11/13/21/23/61/63/71/73

Rear axle

741.413/414/416/420 in model 906.15/25/65

Rear axle

741.413/414/420 in model 900.65

Rear axle

741.428 in model 8AC906.133/631/633/635

with code ZL3 (National version for Latin America)

Rear axle

741.429 in model 8AC906.153/155/655/657

with code ZL3 (National version for Latin America)

Modification notes

28.10.2014

Work procedure adapted to modified repair method.

27.10.2014

Special tool 000 589 30 33 00 replaced by special tool 000 589 31 33 00.

AR35.31-D-0550-07S

Shown on rear axle 741.415

1

Collar nut

2

Screw

3

Joint flange

4

Radial shaft sealing ring

5

Outer tapered roller bearing

6

Compressed ring

7

Drain screw

8

Spacer washer

9

Inner tapered roller bearing

10

Drive pinion

11

Seal

12

Housing cover

13

Oil filler plug

14

Screw

15

Screw

17

Differential

18

Spacer washer

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

Notes on installing a revised final drive ratio

Rear axle 741.412 in model 900.63
Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73
Rear axle 741.413/414/416/420 in model 906.15/25/65
Rear axle 741.413/414/420 in model 900.65
Rear axle 741.428 in model 8AC906.133/631/633/635
with code ZL3 (National version for Latin America)
Rear axle 741.429 in model 8AC906.153/155/655/657
with code ZL3 (National version for Latin America)

AH35.00-N-0001-01A



Remove

1

Drain oil from rear axle



Rear axle 741.428 in model 8AC906.133/631/633/635
with code ZL3 (National version for Latin America)
Rear axle 741.429 in model 8AC906.153/155/655/657
with code ZL3 (National version for Latin America)

AP35.00-A-3501B



Rear axle 741.412 in model 900.63
Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73
Rear axle 741.413/414/416/420 in model 906.15/25/65
Rear axle 741.413/414/420 in model 900.65

AP35.00-D-3501A

2

Remove complete rear axle

AR35.10-D-0010I

3

Clear outside of rear axle housing

4

Fix rear axle in place on assembly device

5

Remove both rear axle shafts

Rear axle 741.412 in model 900.63
Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73
Rear axle 741.413/414/416/420 in model 906.15/25/65
Rear axle 741.413/414/420 in model 900.65
Rear axle 741.428 in model 8AC906.133/631/633/635
with code ZL3 (National version for Latin America)
Rear axle 741.429 in model 8AC906.153/155/655/657
with code ZL3 (National version for Latin America)

Rear axle 741.413/414/416/420 in model 906.155/655/657
with code ZL3 (National version for Latin America)
Rear axle 741.413/414/416/420 in model 906
except code ZL3 (National version for Latin America)
Rear axle 741.413/414/420 in model 900.65
Rear axle 741.429 in model 8AC906.153/155/655/657
with code ZL3 (National version for Latin America)

AR35.30-D-0620B

Rear axle 741.412 in model 900.63
Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73
except code ZL3 (National version for Latin America)
Rear axle 741.428 in model 8AC906.133/631/633/635
with code ZL3 (National version for Latin America)

AR35.30-D-0620H

6

Detach housing cover (12)

7

Remove crown wheel with differential (17)

AR35.30-D-4815-01H

 Spreader

*741589036300

8

Check tapered roller bearing on differential

In event of wear or damage



Replace tapered roller bearing on differential

Detach tapered roller bearings from differential case

AR35.30-D-4301-01S

Install tapered roller bearings on differential housing

AR35.30-D-4300-05A

 Puller

*001589503300

 Collet chuck

*463589023400

 Thrust piece

*463589013400

9

Remove joint flange (3) at drive pinion (10)

AR35.30-D-4670-01A

 Retainer wrench

*717589003100

 Puller

*035589013300

10

Remove drive pinion (10) and compression ring (6)

AR35.31-D-0550-07S

 Puller

*711589033300

 Puller

*000589893300

 Internal extractor

*000589313300

 Counter stay

*000589343300

11

Detach inner tapered roller bearing (9) from drive pinion (10)

AR35.30-D-4300-01A

 The inner tapered roller bearing (9) must be replaced.

 Puller

*001589193300



Install

12

Press inner tapered roller bearing (9) onto drive pinion (10)

AR35.30-D-4300-01A

 Replace inner tapered roller bearing (9).

13

Measure basic dimension on differential (17)

AR35.30-D-4815-02H

Notes on labeling rear axle gear set

AH35.30-N-0001-01A

 Adjusting device

*906589012100

14

Determine thickness of shims (18)

AR35.30-D-4815-03A

Preload of differential bearing

*BE35.30-N-1002-01B

15

Determine difference dimension of drive pinion (10)

AR35.30-D-4815-06H



Drive pinion end face machining changed

Rear axle 741.412 in model 900.63
Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73
except code ZL3 (National version for Latin America)
Rear axle 741.428 in model 8AC906.133/631/633/635
with code ZL3 (National version for Latin America)

BT35.30-D-0006-01A

 Measuring plate

*140589162300

 Adjusting device

*906589012100

 Dial gage

*001589532100

 Dial indicator holder

*363589022100

16

Measure basic dimension at rear axle housing and thickness of shim (8) for adjusting basic dimension

AR35.30-D-4815-07H

Specified basic dimension for rear axle housing

*BE35.30-N-1004-01B

 Adjusting device

*906589012100

 Dial gage

*001589532100

17

Install drive pinion (10) and compression ring (6) with bearing into rear axle housing

AR35.30-D-4815-09H

 Replace compression ring (6).

 Drift

*711589011500

 Insertion tool

*741589004300

 Pressing-on tool

*741589016300

18

Check sealing surface of radial shaft sealing ring (4) in rear axle housing

If damage is present:



Rework sealing surface in rear axle housing

19

Install new radial shaft sealing ring (4)

 Drift

*741589021500

20

Attach joint flange (3) at drive pinion (10)

AR35.30-D-4670-03B

 Replace joint flange (3) and collar nut (1).

Friction torque of drive pinion bearing

*BE35.30-N-1001-01B

 Retainer wrench

*717589003100

 Torque meter

*001589492100

The total friction moment must not be reached by loosening the collar nut (1). If the permissible total friction moment is exceeded:



Install drive pinion (10) again and replace compression ring (6).

21

Check basic dimension again at rear axle housing

AR35.30-D-4815-07H

 The basic dimension engraved on the ring gear must be achieved.

Specified basic dimension for rear axle housing

*BE35.30-N-1004-01B

 Adjusting device

*906589012100

 Dial gage

*001589532100

22

Secure collar nut (1)

23

Install ring gear with differential (17) in rear axle housing

AR35.30-D-4815-04H

 Rear axle 741.412 in model 900.63
Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73
Rear axle 741.413/414/416/420 in model 906.15/25/65
Rear axle 741.413/414/420 in model 900.65
Rear axle 741.428 in model 8AC906.133/631/633/635
with code ZL3 (National version for Latin America)
Rear axle 741.429 in model 8AC906.153/155/655/657
with code ZL3 (National version for Latin America)Bearing bracket of differential housing to axle centerpiece

*BA35.30-N-1002-02A

Rear axle differential gear backlash

*BE35.30-N-1005-01B

 Spreader

*741589036300

 Dial gage

*001589532100

 Dial indicator holder

*363589022100

24

Check contact pattern of ring gear and pinion

AR35.30-D-4815-10H

Engineer's blue, 80 ml tube, BLUE, Diamant

*BR00.45-Z-1002-07A

 Holding fixture

*741589026300

If contact pattern is incorrect



Perform necessary corrections with changed shims (8, 18).

25

Clean sealing surfaces on rear axle housing and housing cover (12)

26

Install housing cover (12) with new seal (11)

 Bolt, cover to rear axle housing

*BA35.25-N-1001-01A

27

Install both rear axle shafts

REAR AXLE all

Rear axle 741.413/414/416/420 in model 906.155/655/657
with code ZL3 (National version for Latin America)
Rear axle 741.413/414/416/420 in model 906
except code ZL3 (National version for Latin America)
Rear axle 741.413/414/420 in model 900.65
Rear axle 741.429 in model 8AC906.153, 906.155/655/657
with code ZL3 (National version for Latin America)

AR35.30-D-0620B

Rear axle 741.412 in model 900.63
Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73
except code ZL3 (National version for Latin America)
Rear axle 741.428 in model 8AC906.133/631/633/635
with code ZL3 (National version for Latin America)

AR35.30-D-0620H

28

Detach rear axle from assembly device

29

Install rear axle

AR35.10-D-0010I

30

Pour in oil at rear axle



Rear axle - oil change

Rear axle 741.428 in model 8AC906.133/631/633/635
with code ZL3 (National version for Latin America)
Rear axle 741.429 in model 8AC906.153/155/655/657
with code ZL3 (National version for Latin America)

AP35.00-A-3501B



Rear axle - oil change

Rear axle 741.412 in model 900.63
Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73
Rear axle 741.413/414/416/420 in model 906.15/25/65
Rear axle 741.413/414/420 in model 900.65

AP35.00-D-3501A


The rear-axle's correct oil filling capacity must be strictly observed.
Otherwise the rear axle may be damaged.

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.412/413/414/416/420/428/429

Rear axle 741.415

BE35.30-N-1001-01B

Friction torque of drive pinion bearing

with radial shaft sealing ring

Nm

4,1...4,5

4,1...4,5

without radial shaft sealing ring

Nm

1,65...3,74

1,65...3,74

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.412/413/414/416/420/428/429

Rear axle 741.415

BE35.30-N-1002-01B

Preload of differential bearing

mm

0,28

0,20

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.412/413/414/416/420/428/429

Rear axle 741.415

BE35.30-N-1004-01B

Specified basic dimension for rear axle housing

mm

74,5

66

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.412/413/414/416/420/428/429

Rear axle 741.415

BE35.30-N-1005-01B

Rear axle differential gear backlash

mm

0,13...0,18

0,13...0,18

 Axle housing

Number

Designation

Rear axle 741.412 in model 900.63
Rear axle 741.412/415/428 in model 906

Rear axle 741.413/414/416/420/429 in model 906
Rear axle 741.413/414/420 in model 900

BA35.25-N-1001-01A

Bolt, cover to rear axle housing

M8

Stage 1

Nm

25

-

Stage 2

°

60

-

M10

Stage 1

Nm

-

35

Stage 2

°

-

45

 Axle drive

Number

Designation

Rear axle 741.415 in model 906

Rear axle 741.412/413/414/416/420/428/429 in model 906
Rear axle 741.412/413/414/420 in model 900

BA35.30-N-1002-02A

Bearing bracket of differential housing to axle centerpiece

M10

Stage 1

Nm

30

-

Stage 2

°

60

-

M121.5

Stage 1

Nm

-

40

Stage 2

°

-

60

M162

Nm

-

-

Repair materials

Number

Designation

Order number

BR00.45-Z-1002-07A

Engineer's blue, 80 ml tube, BLUE, Diamant

Qualitätswerkzeuge Hoffmann GmbH
Haberlandstrasse 55
81241 Munich
Germany
Tel. +49 89 8391-0
Fax +49 89 8391-89
www.hoffmann-group.com
Order no. 085388