Remove and install drive pinion and ring gear with differential · ar3530d4815d · Mercedes-Benz WIS

AR35.30-D-4815D

Remove and install drive pinion and ring gear with differential

06.06.2018

Rear axle

741.980 in model 905

Remove and install drive pinion and ring gear with differential

1	Collar nut
2	Washer
3	Screw
4	Joint flange
5	Radial shaft sealing ring
6	Outer tapered roller bearing
7	Drain screw
8	Compressed ring
9	Inner tapered roller bearing
10	Shim
11	Drive pinion
12	Housing cover seal
13	Housing cover
14	Oil filler plug
15	Screw
16	Bracket
17	Screw
18	Screw
19	Fuse
20	Bearing bracket
21	Threaded ring
22	Tapered roller bearing
23	Ring gear with differential
24	Screw

D35.30-1125-06

25	Removal device for differential
26	Telescopic lifter

D35.30-1145-01

D35.30-1144-01

	Notes on installing a revised final drive ratio		AH35.00-N-0001-01A
	Remove
1	Disconnect anti-roll bar from rear axle and fold down		AR32.35-D-2210D
2	Drain oil from rear axle
			AP35.00-D-3501A
3	Remove propeller shaft from joint flange (4) and strap propeller shaft to one side
4	Remove both rear axle shafts		AR35.30-D-0620C
5	Remove housing cover (13) on rear axle housing
6	Mount removal fixture for differential (25)	 Retainer wrench	*717589003100
7	Remove differential from rear axle housing		AR35.30-D-4815-01B
		 Hook wrench	*905589000700
8	Detach tapered roller bearing (22) from differential housing	 Puller	*001589193300
		 Thrust piece	*905589003400
9.1	Check compensating gears	Rear axle 741.980 in model 905 except code AT5 (Self-locking differential, rear axle)
		If damage is present
		
		Replace compensating gears.
			AR35.30-D-0462A
9.2	Check compensating gears and limited slip differential	Rear axle 741.980 in model 905 with code AT5 (Self-locking differential, rear axle)
		If damage is present
		
		Replace compensating gears and limited slip differential.
			AR35.30-D-0462B
10	Remove removal fixture for differential (25)	 Retainer wrench	*717589003100
11	Detach joint flange (4) from drive pinion (11)		AR35.30-D-4670-01B
		 Retainer wrench	*717589003100
		 Puller	*000589653300
12	Clean teeth on joint flange and shaft	Loctite 7200	*BR00.45-Z-1038-04A
13	Remove radial shaft sealing ring (5) from drive pinion (11)
14	Drive drive pinion (11) out of differential housing and remove with compression ring (8)	 Screw nut onto drive pinion (11) and drive out drive pinion (11) using copper-faced hammer. Otherwise, the drive pinion (11) will be damaged.
15	Detach inner tapered roller bearing (9) from drive pinion (11) and remove spacer disk (10)		AR35.30-D-4300-01B
		 Puller	*001589193300
16	Pull outer race out of outer tapered roller bearing (6)		AR35.30-D-0459-10A
		 Thrust piece	*905589013400
		 Thrust piece	*905589023400
		 Assembly holder	*905589016300
17	Drive outer race out of inner tapered roller bearing (9)
	Install
18	Pull in outer races of outer tapered roller bearing (6) and inner tapered roller bearing (9)		AR35.30-D-4815-09C
		 Replace outer tapered roller bearing (6) and inner tapered roller bearing (9).
		 Installation tool	*905589004300
19	Measure basic dimension on rear axle housing and determine thickness of shim for correcting basic dimension		AR35.30-D-4815-07B
		Friction torque of drive pinion bearing	*BE35.30-N-1001-01B
		 Torque meter	*001589492100
		 Dial gage	*001589532100
		 Adjusting device	*905589002100
20	Press inner tapered roller bearing (9) onto drive pinion (11)		AR35.30-D-4300-01B
		 Replace inner tapered roller bearing (9). Before pressing on, put on the spacer washer (10) determined previously.
		 Sleeve	*716589023300
21	Mount tapered roller bearing (22) onto differential housing		AR35.30-D-4300-05B
		 Drift punch	*905589011500
22	Install drive pinion (11) with bearing into rear axle housing		AR35.30-D-4815-09C
		 Replace compression ring (8).
		 Drift	*711589071500
		 Assembly holder	*905589016300
23	Check sealing surfaces in differential housing	If damage is present
		
		Rework sealing surfaces.
24	Install new radial shaft sealing ring (5) on drive pinion (11)		AR35.30-D-4670-02B
		 Drift punch	*905589001500
25	Attach joint flange (4) onto drive pinion (11)		AR35.30-D-4670-03C
		Friction torque of drive pinion bearing	*BE35.30-N-1001-01B
		Rapid cleaner 7061	*BR00.45-Z-1039-04A
		Loctite sealant 565	*BR00.45-Z-1045-01A
		 Retainer wrench	*717589003100
		 Torque meter	*001589492100
26	Mount removal fixture for differential (25)	 Retainer wrench	*717589003100
27	Install ring gear with differential (23) into rear axle housing		AR35.30-D-4815-04D
		 Ring gear to differential housing	*BA35.30-N-1001-02A
		 Bearing bracket of differential housing to axle centerpiece	*BA35.30-N-1002-02A
		 Bolt, bearing bracket retainer	*BA35.30-N-1004-02A
		Friction torque of differential housing bearing (preload) measured via drive pinion	*BE35.30-N-1006-01B
		Rear axle differential gear backlash	*BE35.30-N-1005-01B
		 Hook wrench	*905589000700
		 Torque meter	*001589492100
		 Dial gage	*001589532100
		 Dial indicator holder	*363589022100
		 Retainer wrench	*717589003100
28	Check contact pattern of gear set and adjust, if necessary		AR35.30-D-4815-10B
		Engineer's blue, 80 ml tube, BLUE, Diamant	*BR00.45-Z-1002-07A
		If adjustment corrected
		
		Check gear backlash and friction torque of bearing, and adjust.
			AR35.30-D-4815-04D
		Friction torque of differential housing bearing (preload) measured via drive pinion	*BE35.30-N-1006-01B
		Rear axle differential gear backlash	*BE35.30-N-1005-01B
		 Bolt, bearing bracket retainer	*BA35.30-N-1004-02A
		 Bearing bracket of differential housing to axle centerpiece	*BA35.30-N-1002-02A
		 Ring gear to differential housing	*BA35.30-N-1001-02A
		 Hook wrench	*905589000700
		 Retainer wrench	*717589003100
		 Dial indicator holder	*363589022100
		 Dial gage	*001589532100
		 Torque meter	*001589492100
29	Mount housing cover (13) with new housing cover seal (12) onto rear axle housing	 Bolt, cover to rear axle housing	*BA35.25-N-1001-01A
		Sealant, SV flame starting system, replaced with: A 001 989 25 20	*BR00.45-Z-1017-01A
30	Install both rear axle shafts		AR35.30-D-0620C
31	Mount propeller shaft onto joint flange (4)
Topical note	Notes on installing propeller shaft		AH41.10-N-0001-01A
		 Bolt, rear propeller shaft to rear axle	*BA41.10-N-1002-01B
		 Open-end wrench	*000589250100
		 Torque wrench handle	*001589442100
32	Pour in oil at rear axle
			AP35.00-D-3501A

Test and adjustment values for rear axle drive

Number	Designation			Rear axle 741.980
BE35.30-N-1001-01B	Friction torque of drive pinion bearing	with radial shaft sealing ring	Nm	1,7...3,38
		without radial shaft sealing ring	Nm	1,65...3,74

Test and adjustment values for rear axle drive

Number	Designation		Rear axle 741.980
BE35.30-N-1005-01B	Rear axle differential gear backlash	mm	0,08...0,30

Test and adjustment values for rear axle drive

Number	Designation		Rear axle 741.980
BE35.30-N-1006-01B	Friction torque of differential housing bearing (preload) measured via drive pinion	Nm	3,4...5,1

 Axle housing

Number	Designation				Rear axle 741.980 in model 905
BA35.25-N-1001-01A	Bolt, cover to rear axle housing	M8	Stage 1	Nm	38
			Stage 2	°	-
		M10	Stage 1	Nm	-
			Stage 2	°	-

 Axle drive

Number	Designation				Rear axle 741.980 in model 905
BA35.30-N-1001-02A	Ring gear to differential housing	M121	12.9	Nm	-
		M141.5		Nm	235

 Axle drive

Number	Designation				Rear axle 741.980 in model 905
BA35.30-N-1002-02A	Bearing bracket of differential housing to axle centerpiece	M10	Stage 1	Nm	-
			Stage 2	°	-
		M121.5	Stage 1	Nm	-
			Stage 2	°	-
		M162		Nm	280

 Axle drive

Number	Designation			Rear axle 741.980 in model 905
BA35.30-N-1004-02A	Bolt, bearing bracket retainer	M8	Nm	27

 Propeller shaft

Number	Designation				Model 690.6, 901, 902, 905 (except 905.613) Model 903.0/4/6, 904.0/4, 904.6 (except 904.663) except code ZG1 (Engageable all-wheel drive) except code ZG2 (Permanent all-wheel drive) except code ZG3 (Engageable all-wheel drive with gear reduction) Model 905.613 Except Sprinter low floor minibus
BA41.10-N-1002-01B	Bolt, rear propeller shaft to rear axle	M101	Stage 1	Nm	70
			Stage 2	°	-

905 589 01 15 00

Drift punch

905 589 00 43 00

Installation tool

716 589 02 33 00

Sleeve

905 589 01 34 00

Thrust piece

000 589 65 33 00

Puller

905 589 01 63 00

Assembly holder

905 589 02 34 00

Thrust piece

000 589 25 01 00

Open-end wrench

905 589 00 15 00

Drift punch

905 589 00 07 00

Hook wrench

905 589 00 34 00

Thrust piece

905 589 00 21 00

Adjusting device

001 589 53 21 00

Dial gage

001 589 19 33 00

Puller

001 589 44 21 00

Torque wrench handle

001 589 49 21 00

Torque meter

363 589 02 21 00

Dial indicator holder

717 589 00 31 00

Retainer wrench

711 589 07 15 00

Drift

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-1017-01A	Sealant, SV flame starting system, replaced with: A 001 989 25 20	A 000 989 54 20
BR00.45-Z-1038-04A	Loctite 7200	Henkel AG & Co. KGaA http://www.loctite.de
BR00.45-Z-1039-04A	Rapid cleaner 7061	Henkel AG & Co. KGaA http://www.loctite.de
BR00.45-Z-1045-01A	Loctite sealant 565	A 004 989 18 20

Referenced documents

ah3500n000101a Notes on installing a revised final drive ratio
ah4110n000101a Notes on installing propeller shaft
ap3500d3501a Rear axle - oil change
ar3235d2210d Remove/install anti-roll bar on rear axle
ar3530d045910a Removing outer races on drive pinion bearing
ar3530d0462a Disassemble, assemble ring gear and differential
ar3530d0462b Disassemble, assemble ring gear with differential
ar3530d0620c Remove/install rear axle shaft
ar3530d430001b Pull tapered roller bearing off drive pinion, press on
ar3530d430005b Installing tapered roller bearings on differential case
ar3530d467001b Detaching joint flange from drive pinion
ar3530d467002b Installing radial sealing ring on drive pinion
ar3530d467003c Install joint flange at drive pinion
ar3530d467003c
ar3530d481501b Removing differential from rear axle housing
ar3530d481504d Install differential in rear axle housing
ar3530d481507b
ar3530d481507b Measuring basic dimension at rear axle housing and determining thickness of shimfor correcting basic dimension
ar3530d481509c Install drive pinion with bearing in rear axle housing
ar3530d481510b Check contact pattern of gear assembly