Remove/install front axle gear cover · ar3330d7635a · Mercedes-Benz WIS

AR33.30-D-7635A

Remove/install front axle gear cover

9.10.08

MODELS 903.0 /4 /6, 904.0 /4 /6 with CODE (ZG1) Engageable all-wheel drive

MODELS 903.0 /4 /6, 904.0 /4 /6 with CODE (ZG2) Permanent all-wheel drive

MODELS 903.0 /4 /6, 904.0 /4 /6 with CODE (ZG3) Reduction ratio for all-wheel drive

D33.30-1117-06

1 Grooved nut

2 Locking plate

3 Grooved nut

4 Front axle gear housing

5 Gasket

6 Front axle gear housing cover with ring gear flange

7 Washer

8 Screw

9 Left front axle shaft flange

	Remove
1	Disconnect front axle drive shafts from front axle gear at the flange		AR33.30-D-0100A
2	Remove front axle gear propeller shaft		AR41.10-D-0070A
3	Unscrew oil filler plug and oil drain plug, drain oil
	Front axle - oil change		AP33.00-D-3301A
4	Remove front axle gear	Model 903.0/4, 904.0/4	AR33.30-D-0525A
		Model 903.6, 904.6	AR33.30-D-0525B
	Dismantling
5	Remove left front axle shaft flange (9)	 Drive out with plastic mallet or lever out with assembly tool.
6	Remove front axle gear housing with ring gear flange (6)		AR33.30-D-7635-01A
		 Claw-type wrench	*309589010700
7	Check needle roller bearing and radial shaft sealing ring in front axle gear housing cover for wear and damage and replace if necessary	 Removal:
		 Drift	*366589021500
		 Installation: Before installation (2), coat new radial shaft sealing ring on the outer sealing surface with sealing compound.
		 Drift	*360589001500
		 Drift	*901589001500
		Varybond model 1350, high-strength (green)	*BR00.45-Z-1077-02A
	Assembling
8	Clean contact surfaces of front axle gear housing (4) and clean front axle gear housing cover (6)
9	Install front axle gear housing with ring gear flange (6)		AR33.30-D-7635-02A
		Gear backlash	*BE33.30-N-1002-03B
			*BA33.30-N-1012-03A
			*BA33.30-N-1013-03A
		 Claw-type wrench	*309589010700
		 Gage stand	*363589022100
		 Dial indicator	*001589532100
10	Install front axle shaft flange (9)	 Drive in using plastic mallet.
	Install
11	Install front axle gear	Model 903.0/4, 904.0/4	AR33.30-D-0525A
		Model 903.6, 904.6	AR33.30-D-0525B
12	Install front axle gear propeller shaft		AR41.10-D-0070A
13	Connect front axle drive shafts to front axle gear at the flange		AR33.30-D-0100A
14	Pour in oil
	Front axle - oil change		AP33.00-D-3301A

Test values for through-drive

Number	Designation		Models 903.0/4/6 and 904.0/4/6 with code ZG1/ZG2/ZG3


BE33.30-N-1002-03B	Gear backlash of front axle drive (measured at drive pinion flange)	mm	0.23...0.28

 Front axle gear

Number	Designation			Models 903.0/4, 904.0/4 with Code ZG1/ZG2/ZG3	Models 903.6, 904.6 with code ZG1/ZG2/ZG3


BA33.30-N-1012-03A	Jam nut, hollow shaft to transmission housing		Nm	350	350
BA33.30-N-1013-03A	Bolt, front axle housing cover to transmission housing	8.8	Nm	10	-
		10.9	Nm	20	20

360 589 00 15 00

Drift

Prong wrench

Drift

309 589 01 07 00

366 589 02 15 00

901 589 00 15 00

Dial indicator

001 589 53 21 00

363 589 02 21 00

Dial indicator holder

Repair materials

Number	Designation	Order number
BR00.45-Z-1077-02A	Varybond model 1350, high-strength (green)	Wingerath Vertrieb & Service Wilhelm-Hecking-Str. 2 58099 Hagen Germany Tel. +49 2331 396271 Fax + 49 2331 396272 www.wvs-wingerath.de

Referenced documents

ap3300d3301a Front axle - oil change
ar3330d0100a Removing and installing front axle drive shaft
ar3330d0525a Removing and installing front axle gear
ar3330d0525b Remove/install front axle gear
ar3330d763501a Remove front axle housing cover
ar3330d763502a Installing front axle housing cover
ar4110d0070a Remove/install front axle differential propeller shaft