Remove and install drive pinion and ring gear with differential

AR35.30-D-4815S

18.02.2020

Rear axle	741.421/422/423/453/454/455 in model 906
Rear axle	741.421/455 in model 900

Modification notes

04.12.2018

Workshop equipment 000 588 00 31 01 Adapter replaced by 000 588 07 31 00 Axle mounting adapter.

Operation step 4

	Remove
1	Drain oil from rear axle
			AP35.00-D-3501A
2	Remove complete rear axle	Rear axle 741.421/423 in model 906.11/13/21/23/61/63/71/73 Rear axle 741.421/455 in model 900 Rear axle 741.422/453/454/455 in model 906.15/25/65	AR35.10-D-0010I
3	Clear outside of rear axle housing
4	Fix rear axle in place on assembly device
	000 588 00 31 00 Assembly stand for cars		WS01.00-N-3028B
	000 588 07 31 00 Axle mount adapter		WS33.00-N-0249B
5	Remove both rear axle shafts	Rear axle 741.422/453/454/455 in model 906 Rear axle 741.455 in model 900	AR35.30-D-0620B
		Rear axle 741.421 in model 900 Rear axle 741.421/423 in model 906	AR35.30-D-0620H
6	Remove joint flange at drive pinion		AR35.30-D-4670-01S
		 Retainer wrench	*717589003100
		 Puller	*035589013300
7	Detach end cover from rear axle housing		AR35.31-D-0554H
8	Remove differential from rear axle housing		AR35.30-D-4815-01S
		 Spreader	*741589036300
9	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-4300-05S
		 Puller	*001589503300
		 Thrust piece	*463589013400
		 Collet chuck	*463589023400
10	Remove radial shaft sealing ring		AR35.31-D-0530-06S
		 Drift	*741589021500
11	Remove drive pinion with bearing and spacer washer from rear axle housing		AR35.31-D-0550-07S
		 Internal extractor	*000589313300
		 Counter stay	*000589343300
		 Puller	*000589893300
12	Check outer tapered roller bearing and inner tapered roller bearing	If wear or damage are present,
		
		Replace outer tapered roller bearings and inner tapered roller bearings.
			AR35.30-D-4300-01S
		 Puller	*001589193300
13	Clean sealing surfaces and rear axle housing on inside	Loctite 7063 (400 ml) cleaning spray	*BR00.45-Z-1046-04A
		Loctite 7200	*BR00.45-Z-1038-04A
	Install
14	Measure basic dimension at differential		AR35.30-D-4815-02S
		 For the following determination of the thickness of the spacer washers, the internal size of the rear axle housing and the differential must be measured.
		 Adjusting device	*906589012100
15	Determine thickness of spacer washers for the differential on the rear axle housing		AR35.30-D-4815-03S
		Preload of differential bearing	*BE35.30-N-1002-01B
16	Measure difference dimension of drive pinion		AR35.30-D-4815-06S
		 For the following determination of the thickness of the spacer washers, the difference dimension for the drive pinion must be determined.
		 Dial indicator holder	*363589022100
		 Dial gauge	*001589822100
		 Adjusting device	*906589012100
		 Measuring plate	*140589162300
17	Measuring basic dimension at rear axle housing and determining thickness of shim for correcting basic dimension		AR35.30-D-4815-07S
		Specified basic dimension for rear axle housing	*BE35.30-N-1004-01B
		 Adjusting device	*906589012100
		 Dial gage	*001589532100
18	Installing drive pinion with bearing in rear axle housing		AR35.30-D-4815-09S
		 Nut, joint flange to drive pinion	*BA35.30-N-1005-01A
		Friction torque of drive pinion bearing	*BE35.30-N-1001-01B
		 Torque meter	*001589492100
		 Retainer wrench	*717589003100
		 Measuring device	*741589022100
		 Insertion tool	*741589004300
		 Pressing-on tool	*741589016300
19	Install radial shaft sealing ring		AR35.31-D-0530-06S
		 Drift	*741589021500
20	Install joint flange at drive pinion		AR35.30-D-4670-03S
		 Use new joint flange. Otherwise leakage may occur.
		 Replace collar nut.
		 Nut, joint flange to drive pinion	*BA35.30-N-1005-01A
		 Retainer wrench	*717589003100
21	Secure collar nut on joint flange drive pinion		AR35.30-D-4670-04S
22	Install differential into rear axle housing		AR35.30-D-4815-04S
		 Bearing bracket of differential housing to axle centerpiece	*BA35.30-N-1002-02A
		Rear axle differential gear backlash	*BE35.30-N-1005-01B
		 Dial gage	*001589532100
		 Dial indicator holder	*363589022100
		 Spreader	*741589036300
23	Mount end cover to rear axle housing		AR35.31-D-0554H
		 Replace seal.
24	Install both rear axle shafts	Rear axle 741.422/453/454/455 in model 906 Rear axle 741.455 in model 900	AR35.30-D-0620B
		Rear axle 741.421 in model 900 Rear axle 741.421/423 in model 906	AR35.30-D-0620H
25	Detach rear axle from assembly device
26	Install complete rear axle	Rear axle 741.421/423 in model 906.11/13/21/23/61/63/71/73 Rear axle 741.421/455 in model 900 Rear axle 741.422/453/454/455 in model 906.15/25/65	AR35.10-D-0010I
27	Pour in oil at rear axle
			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 741.421/422/453/454/455/456	Rear axle 741.423
BE35.30-N-1001-01B	Friction torque of drive pinion bearing	with radial shaft sealing ring	Nm	1,85...3,94	1,85...3,94
		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 741.421/422/453/454/455/456	Rear axle 741.423
BE35.30-N-1002-01B	Preload of differential bearing	mm	0,20	0,20

Test and adjustment values for rear axle drive

Number	Designation			Rear axle 741.421/422/453/454/455/456	Rear axle 741.423
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 741.421/422/453/454/455/456	Rear axle 741.423
BE35.30-N-1005-01B	Rear axle differential gear backlash	mm	0,10...0,15	0,10...0,15

 Axle drive

Number	Designation				Rear axle 741.423	Rear axle 741.421/422/453/454/455/456
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	-	-

 Rear axle shaft

Number	Designation		Rear axle 741.421/423	Rear axle 741.422/453/454/455/456
BA35.30-N-1005-01A	Nut, joint flange to drive pinion		200	200

Remove and install drive pinion and ring gear with differential

741 589 02 21 00

Measuring device

000 589 31 33 00

Internal extractor

741 589 02 15 00

Drift

741 589 03 63 00

Spreader

741 589 01 63 00

Pressing-on tool

000 589 89 33 00

Puller

463 589 02 34 00

Collet chuck

001 589 53 21 00

Dial gage

001 589 19 33 00

Puller

140 589 16 23 00

Measuring plate

741 589 00 43 00

Insertion tool

001 589 82 21 00

Dial gauge

001 589 49 21 00

Torque meter

000 589 34 33 00

Counter stay

906 589 01 21 00

Adjusting device

001 589 50 33 00

Puller

463 589 01 34 00

Thrust piece

035 589 01 33 00

Puller

363 589 02 21 00

Dial indicator holder

717 589 00 31 00

Retainer wrench

Repair materials

Number	Designation	Order number
BR00.45-Z-1038-04A	Loctite 7200	Henkel AG & Co. KGaA http://www.loctite.de
BR00.45-Z-1046-04A	Loctite 7063 (400 ml) cleaning spray	A 001 986 71 71 09

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