Remove and install drive pinion and ring gear with differential

AR35.30-D-4815C

Remove and install drive pinion and ring gear with differential

13.02.2020

Rear axle

741.52 in model 611

Rear axle

741.530 in model 667

Rear axle

741.540 in model 667

Rear axle

741.55 in model 667, 668

1

Collar nut

2

Bolts

3

Spring lock washers

4

Nuts

5

Joint flange

6

Radial shaft sealing ring

7

Outer tapered roller bearing

8

Compressed ring

9

Drain screw

10

Shim

11

Inner tapered roller bearing

12

Drive pinion

13

Housing cover seal

14

Housing cover

15

Oil filler plug

16

Screw

17

Shims

18

Ring gear with differential

19

Bearing bracket

20

Screw

21

Collar nut

22

Drive shaft

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Special instructions for lifting and supporting vehicle

Rear axle 741.55 in model 668

AH00.60-N-0100-01B



Remove

1

Detach complete wheels at rear axle

 Support with jack stands.

2

Drain oil from rear axle

3

Remove propeller shaft from joint flange (5)

Rear axle 741.52 in model 611
Rear axle 741.530 in model 667
Rear axle 741.540 in model 667
Rear axle 741.55 in model 667, 668

Rear axle 741.55 in model 668

AR41.10-D-0050A

4

Remove both drive shafts (22)

5

Remove housing cover (14) from rear axle housing

6

Remove differential from rear axle housing

AR35.30-D-4815-01A

 Spreader

*460589053100

7

Check tapered roller bearing

If damage is present



Replace tapered roller bearing.

8

Detach joint flange (5) from drive pinion (12)

AR35.30-D-4670-01A

 Retainer wrench

*717589003100

 Puller

*035589013300

9

Drive the drive pinion (12) out of the rear axle housing and remove with compression ring (8)

10

Check tapered roller bearing on drive pinion

If damage is present



Replace tapered roller bearing on drive pinion.

AR35.30-D-4300-01A

 Puller

*001589193300

11

Drive out at flange on outer tapered roller bearing (7) and radial shaft sealing ring (6)

 Drift

*343589031500

12

Drive out inner tapered roller bearing (11) on pinion side and remove with spacer disk (10)

 Rear axle 741.52/530/540
Thrust piece

*601589016300

 Rear axle 741.55
Thrust piece

*601589106300



Install

13

Measure basic dimension at differential

Rear axle 741.52/530/540/55
except code A71 (Differential lock rear axle)

AR35.30-D-4815-02A

Rear axle 741.52/530/540/55
with code A71 (Differential lock rear axle)

AR35.30-D-4815-02B

 Adjustment device

*601589002100

 Rear axle 741.52/530/540/55
with code A71 (Differential lock rear axle)
Ring

*460589036300

14

Determine thickness of spacer washers (17) for ring gear with differential (18) on rear axle housing

AR35.30-D-4815-03A

Preload of differential bearing

*BE35.30-N-1002-01B

15

Install ring gear with differential (18) in rear axle housing

AR35.30-D-4815-04A

 Do not mount bearing bracket yet and do not yet check gear backlash.

 Spreader

*460589053100

16

Check friction torque of differential

AR35.30-D-4815-05A

Tractive force for determining the friction torque of differential housing bearing (preload)

*BE35.30-N-1003-01B

17

Remove differential again with shims

18

Measure difference dimension of drive pinion

AR35.30-D-4815-06A



Drive pinion end face machining changed

BT35.30-D-0006-01A

 Measuring plate

*140589162300

 Measuring piece

*601589012300

 Dial gage

*001589532100

 Dial indicator holder

*363589022100

19

Measure basic dimension at rear axle housing and determine thickness of spacer washer (10) for adjusting basic dimension

AR35.30-D-4815-07A

AR35.30-D-4815-08A

Specified basic dimension for rear axle housing

*BE35.30-N-1004-01B

 Adjustment device

*601589002100

 Dial gage

*001589532100

 Measuring piece

*601589012300

 Rear axle 741.52/530/540/55
with code A71 (Differential lock rear axle)
Ring

*460589036300

20

Installing drive pinion with bearing in rear axle housing

AR35.30-D-4815-09A

 Rear axle 741.52/530/540
Replace compression ring (8).

 Drift

*318589011500

 Support bridge

*601589026300

 Drift

*000589101500

 Drift

*312589051500

 Drift

*624589001500

21

Install new radial shaft sealing ring (6) on drive pinion

AR35.30-D-4670-02A

Sealant, SV flame starting system, replaced with: A 001 989 25 20

*BR00.45-Z-1017-01A

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

 Drift

*460589151500

22

Attach joint flange (5) onto drive pinion (12)

AR35.30-D-4670-03B

Friction torque of drive pinion bearing

*BE35.30-N-1001-01B

 Retainer wrench

*717589003100

 Torque meter

*001589492100

23

Check basic dimension again at rear axle housing

AR35.30-D-4815-07A

 Ground gear set: The specified basic dimension must be reached.
Lapped gear set: The basic dimension engraved on the ring gear must be reached.

Specified basic dimension for rear axle housing

*BE35.30-N-1004-01B

 Adjustment device

*601589002100

 Dial gage

*001589532100

 Measuring piece

*601589012300

 Rear axle 741.52/530/540/55
with code A71 (Differential lock rear axle)
Ring

*460589036300

24

Secure collar nut (1)

AR35.30-D-4670-04A

25

Install differential again in rear axle housing

AR35.30-D-4815-04A

 Rear axle 741.52Bearing bracket of differential housing to axle centerpiece

*BA35.30-N-1002-02A

Rear axle differential gear backlash

*BE35.30-N-1005-01B

 Spreader

*460589053100

 Dial gage

*001589532100

 Dial indicator holder

*363589022100

26

Check contact pattern of ring gear and pinion

AR35.30-D-4815-10A

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

*BR00.45-Z-1002-07A

 Holding device

*601589014000

27

Mount housing cover (14) with new housing cover seal (13) onto rear axle housing

 Bolt, cover to rear axle housing

*BA35.25-N-1001-01A

28

Install both drive shafts (22)

 Rear axle 741.52/530/540/550Nut, rear axle shaft to hub

*BA35.30-N-1003-01A

29

Mount propeller shaft onto joint flange (5)

 Rear axle 741.52 in model 611Bolt, rear propeller shaft to rear axle

*BA41.10-N-1002-01B

 Rear axle 741.530/540/55 in model 667Bolt, rear drive shaft to rear axle

*BA41.10-N-1002-01D

30

Pour in oil at rear axle

31

Attach complete wheels

 Rear axle 741.52 in model 611Wheel bolt and wheel nut

*BA40.10-N-1001-01A

 Rear axle 741.530/540/55 in model 667, 668Wheel nut

*BA40.10-N-1001-01B

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.52/53/54/55

BE35.30-N-1001-01B

Friction torque of drive pinion bearing

with radial shaft sealing ring

Nm

2,5...3

without radial shaft sealing ring

Nm

1,65...3,74

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.52/53/54/55

BE35.30-N-1002-01B

Preload of differential bearing

mm

0,16

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.52/53/54/55

BE35.30-N-1003-01B

Tractive force for determining the friction torque of differential housing bearing (preload)

N

35...45

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.52/53/54/55

BE35.30-N-1004-01B

Specified basic dimension for rear axle housing

mm

66

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.52/53/54/55

BE35.30-N-1005-01B

Rear axle differential gear backlash

mm

0,10...0,15

 Axle housing

Number

Designation

Rear axle 741.52/53/54/55

BA35.25-N-1001-01A

Bolt, cover to rear axle housing

M8

Stage 1

Nm

65

Stage 2

°

-

M10

Stage 1

Nm

-

Stage 2

°

-

 Axle drive

Number

Designation

Rear axle 741.52

BA35.30-N-1002-02A

Bearing bracket of differential housing to axle centerpiece

M10

Stage 1

Nm

70

Stage 2

°

-

M121.5

Stage 1

Nm

-

Stage 2

°

-

M162

Nm

-

 Rear axle shaft

Number

Designation

Rear axle 741.52
Rear axle 741.530/540

Rear axle 741.550

BA35.30-N-1003-01A

Nut, rear axle shaft to hub

M10

Stage 1

Nm

65

65

Stage 2

Nm

-

-

Stage 3

°

-

-

M12x1.5

Nm

-

145

 Wheels

Number

Designation

Model 601, 602, 611

BA40.10-N-1001-01A

Wheel bolt and wheel nut

Nm

170

 Wheels

Number

Designation

Model 667, 668, 670

BA40.10-N-1001-01B

Wheel nut

M14x1.5

Nm

180

M18x1.5

Nm

250

 Propeller shaft

Number

Designation

Model 601, 602, 611

BA41.10-N-1002-01B

Bolt, rear propeller shaft to rear axle

M101

Stage 1

Nm

76

Stage 2

°

-

 Drive shaft

Number

Designation

Model 667

BA41.10-N-1002-01D

Bolt, rear drive shaft to rear axle

M101

Nm

70

M121

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

BR00.45-Z-1008-06A

Grease, silicone-based, 100 g

A 001 989 28 51

BR00.45-Z-1017-01A

Sealant, SV flame starting system, replaced with: A 001 989 25 20

A 000 989 54 20