Remove/install flanged pipe · ar3330d8610a · Mercedes-Benz WIS

AR33.30-D-8610A

Remove/install flanged pipe

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

D33.30-1118-06

1 Front axle gear housing

2 Tapered roller bearing

3 Tapered roller bearing outer race

4 Gasket

5 Gasket

6 Hub drive gear

7 Locking plate

8 Grooved nut

9 Washer

10 Screw

11 Flanged pipe

	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
5	Remove left front axle shaft flange	 Drive out with plastic mallet or lever out with assembly tool.
6	Remove front axle housing cover		AR33.30-D-7635-01A
7	Unlock slotted nut (8)
8	Unscrew slotted nut (8) and remove with locking plate (7)	 Use screwdriver to lock gear wheel/hub reduction gear (6).
		 Claw-type wrench	*309589010700
9	Unscrew bolts (10) and remove with washers (9).
10	Hammer differential housing out of gear wheel/hub reduction gear (6) and remove with flanged pipe (11) and gasket (4)
11	Check tapered roller bearing (2) and tapered roller bearing outer race (3) for wear and damage and replace if necessary	 When replacing one or both tapered roller bearings (the second taper roller bearing is located in the cover of the flanged pipe), the thickness of the shim in front of the second bearing in the flanged pipe cover must be re-determined otherwise the front axle gear may become damaged. See 
		Remove differential housing bearing	AR33.30-D-8610-01A
		 Claw-type wrench	*309589010700
		 Puller	*001589503300
		 Tensioning clamp	*000589613400
		 Tensioning clamp	*140589023400
		 Thrust piece	*463589013400
		 Drift	*305589001500
		 Internal extractor	*000589683300
		 Countersupport	*000589713300
		Install differential housing bearing	AR33.30-D-8610-02A
		Friction torque	*BE33.30-N-1002-01C
			*BA33.30-N-1007-03A
			*BA33.30-N-1008-03A
			*BA33.30-N-1009-03A
			*BA33.30-N-1010-03A
		 Claw-type wrench	*309589010700
		 Gage stand	*363589022100
		 Dial indicator	*001589532100
		 Puller	*001589503300
		 Tensioning clamp	*140589023400
		 Thrust piece	*463589013400
		 Torque meter	*001589492100
		 Drift	*312589051500
	Install
12	Clean contact surfaces of flanged pipe (11) and front axle housing (1)
13	Insert gear wheel/hub reduction gear (6) into the transmission housing	 Note installation position: The projecting contact surface must point towards the differential.
14	Position flanged pipe (11) with new gasket (12) on the transmission housing and tighten securely with bolts (10) and washers (9)		*BA33.30-N-1007-03A
15	Mount new locking plate (7) on the differential housing
16	Tighten grooved nut (8)	 Use screwdriver to lock gear wheel/hub reduction gear (6).
			*BA33.30-N-1008-03A
		 Claw-type wrench	*309589010700
17	Total friction torque moment (friction torque) of differential housing	Friction torque	*BE33.30-N-1002-01C
			*001589492100
		 The measured value must match the specified friction coefficient. If the specified value is dropped below or exceeded the shim must be re-determined. See 
		Install differential housing bearing	AR33.30-D-8610-01A
		Friction torque	*BE33.30-N-1002-01C
			*BA33.30-N-1007-03A
			*BA33.30-N-1008-03A
			*BA33.30-N-1009-03A
			*BA33.30-N-1010-03A
		 Claw-type wrench	*309589010700
		 Gage stand	*363589022100
		 Dial indicator	*001589532100
		 Puller	*001589503300
		 Tensioning clamp	*140589023400
		 Thrust piece	*463589013400
		 Torque meter	*001589492100
		 Drift	*312589051500
18	Secure locking plate (7)
19	Install front axle housing cover (8)		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
20	Install left-hand front axle shaft flange	 Drive in using plastic mallet.
21	Install front axle housing	Model 903.0/4, 904.0/4	AR33.30-D-0525A
		Model 903.6, 904.6	AR33.30-D-0525B
22	Pour in oil
	Front axle - oil change		AP33.00-D-3301A
23	Install front axle gear propeller shaft		AR41.10-D-0070A
24	Connect front axle drive shafts to front axle gear at the flange		AR33.30-D-0100A

Test values for crown wheel with differential

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


BE33.30-N-1002-01C	Friction torque of differential housing bearing	Nm	3...5

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-1007-03A	Bolt, flanged pipe to transmission housing	8.8	Nm	25	-
		10.9	Nm	33	33
BA33.30-N-1008-03A	Nut, differential gear to transmission housing		Nm	350	350
BA33.30-N-1009-03A	Bolt, flanged pipe cover to flanged pipe	8.8	Nm	10	-
		10.9	Nm	12	12
BA33.30-N-1010-03A	Bolt, right transmission bracket to flanged pipe cover	8.8	Nm	10	-
		10.9	Nm	12	12
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