Remove/install front axle gear rubber mounts

AR33.30-D-5000H

Remove/install front axle gear rubber mounts

27.10.10

 

Remove/install

 Danger!

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

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

AS00.00-Z-0010-01A



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A

1

Remove air filter housing

Engine 642

AR09.10-D-1150SF

Engine 646

AR09.10-D-1150SD

Engine 651

AR09.10-D-1150WE

2

Remove the washer fluid reservoir of the windshield washer system

AR82.35-D-6000SD

3

Unclip cover of fan shroud and remove fan shroud from radiator

 To enable the engine to be raised far enough. See: 

Remove/install fan shroud

Engine 646

AR20.40-D-6800SD

Engine 642

AR20.40-D-6800SF

Engine 651

AR20.40-D-6800WE

4

Raise vehicle

AR00.60-D-1000H

5

Secure vehicle on vehicle lift

AR00.60-D-0100H

6

Undo bolts (3) for both front engine mounts



*BA22.10-N-1001-01S

7

Mount engine carrier arm and raise engine

Engine 642

AR33.10-D-0100-01SF



*639589006100



*906589016100



*906589036100

Engine 646

AR33.10-D-0100-01SD



*639589006100



*906589016100

Engine 651

AR33.10-D-0100-01NG



*639589006100



*906589016100

8

Detach driveshaft from front final-drive unit

AR41.10-D-0070H

9

Remove bolts (4, 5, 6) from front axle transmission (2)

 Installation: Pay attention to the freedom of stress of the rubber mounts as well as the tightening sequence (a, b, c, d) as per the tightening procedure.



*BA33.30-N-1019-03A

10

Pry front axle transmission (2) out of axle/engine subframe

 Secure front axle transmission (2) using suitable base against damage and tipping over.

 Make sure that when lifting out the front axle transmission (2) that the output flange on the left side (max. 3 cm) is not pulled too far out of the axle housing as otherwise the output flange may slip out of the gearing in the front axle transmission (2) and damage the sealing ring.

 Lift front axle transmission (2) only far enough out until the rubber mounts can be removed and installed using the special tool.

11

Remove bearing bushings on front axle gear housing

 When removing and installing the bushings, only use the  supplementary set's  spindle and  thrust piece.

AR33.30-D-5000-01H



*001589513300



*639589034300



*639589034399



*652589003321



*652589003323

12

Remove rubber mount from front axle gear bracket

AR33.30-S-5000-02S



*639589044300

Vaseline

*BR00.45-Z-1015-06A

13

Reinstall in opposite order

Number

Designation

Engine 642.9

Engine 646.9

BA22.10-N-1001-01S

Bolt, front engine mount to front axle carrier

Nm

58

58

Number

Designation

Engine 651

BA22.10-N-1001-01S

Bolt, front engine mount to front axle carrier

Nm

58

Number

Designation

Model
906
with code ZG1/ZG2/
ZG3/ ZG4

BA33.30-N-1019-03A

Bolt securing front axle gear to front axle carrier

10.9

Nm

58

Number

Designation

Order number

BR00.45-Z-1015-06A

Vaseline

Karl Käppler GmbH & Co. KG, Liebknechtstr. 48,
D-70565 Stuttgart
Tel. +49 711 7868-481
Fax +49 711 7868-489
www.karl-kaeppler.de