Disassemble, assemble differential

AR35.30-W-0465B

Disassemble, assemble differential

16.11.09



Disassemble

1

Remove differential assembly.

Model designation 771.000

AR35.30-W-0432F

Model designation 745.79

AR35.30-W-0432C

2

Remove ring gear with differential

AR35.30-W-0464C

3

Detach tapered roller bearing (14) and (1)



*000589453300



*327589006300



*714589033400



*001589413300

4

Remove hexagon head bolts (15 and 16) from the upper differential housing half (2)



 Place differential in support and clamp with suitable thrust piece.

*337589023100

5

Separate top half of differential housing (2) from bottom half of differential housing (13)

 Hammer down ring gear (3) using a rubber hammer.

6

Remove differential side gear (5) with thrust ring (4) from differential spider (10)

7

Remove differential spider (10) with differential bevel gears (8) from bottom half of differential housing (13)

8

Remove pressure plates (6), differential pinion (8) with thrust plates (9) from differential spider (10)

 When taking off the differential pinions, pay attention to bearing needles (7) which have become free.

9

Remove differential side gear (11) and thrust ring (12) from bottom half of differential housing (13)



Assemble

10

Insert pressure plate (12) and differential side gear (11) in the lower half of the differential housing (13)

 Lubricate pressure plate.

*BR00.45-Z-1023-06A

11

Slide thrust plates (9) onto bearing shafts of differential spider (10)

 The arched side of thrust plate (9) must point towards the differential pinion (8).

12

Mount differential pinions (8) centrally on the bearing shafts of the differential spider (10)

13

Insert bearing needles (7) into the differential pinions (8)

 Insert bearing needles with long-life grease. For each differential, only install bearing needles of the same sort.

*BR00.45-Z-1001-06A

14

Place pressure plates (6) on the differential pinions (8)

 Lubricate pressure plates.

*BR00.45-Z-1023-06A

15

Install differential spider (10) in bottom half of differential housing (13)

16

Place differential side gear (5) with thrust washer (4) on the differential spider (10)

 Lubricate pressure plate.

*BR00.45-Z-1023-06A

17

Place top half of differential housing (2) on bottom half of differential housing (13)

 Observe markings on the housing halves. Place housing halves on each other so that the markings align. Only assemble housing halves with the same identification number.

18

Assemble upper differential housing halves (2) and lower differential housing half (13)

 Use new hexagon head bolts (16) and screw in finger-tight.

19

Attach ring gear (3)

 Use new hexagon head bolts (15) and screw in finger-tight.

20

Tighten hexagon head bolts (15) and (16)

 Upper differential housing half/ ring gear BM. 771.000

*BA35.30-N-1007-03E

Model designation 745.79

*BA35.30-N-1001-03C

 Upper/lower differential housing half BM. 771.000

*BA35.30-N-1008-03E

Model designation 745.79

*BA35.30-N-1002-03C

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

21

Slide tapered roller bearings (1 and 14) all the way onto differential

 Before sliding on, heat up tapered roller bearings to approx. 110 °C

22

Install crown wheel with differential

AR35.30-W-0464C

23

Install differential assembly

Model designation 771.000

AR35.30-W-0432F

Model designation 745.79

AR35.30-W-0432C

Number

Designation

Rear axle 771.000/001

BA35.30-N-1007-03E

Bolt, upper half of differential housing to ring gear

Stage 1

Nm

60

Stage 2

Nm

160

Stage 3

°

90

BA35.30-N-1008-03E

Bolt, top half to lower half of differential housing

M141.5

Stage 1

Nm

60

Stage 2

Nm

250

Stage 3

°

90

Number

Designation

Rear axle 745.79

BA35.30-N-1001-03C

Bolt, top half of differential cover to ring gear

M121.0

STAGE 1

Nm

60

Stage 2

Nm

160

Stage 3

°

90

BA35.30-N-1002-03C

Bolt, top half to bottom half of differential housing

M141.5

STAGE 1

Nm

60

Stage 2

Nm

250

Stage 3

°

90

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11

BR00.45-Z-1023-06A

Hypoid gear oil

A 000 989 28 03