Disassemble/assemble differential

AR35.30-Y-0465A

Disassemble/assemble differential

19.08.2020

Rear axle

400.750 in model 831.001/002/005

Disassemble drive head

1

Special tool lifting hook 090 589 00 59 00

4

Mounting bracket 090 589 39 31 00

2

Special tool drive head overhaul stand 090 589 00 99 00

5

Dial gauge

3

Rotating bracket 090 589 19 62 00

6

Split pins

7

Bearing cap bolts

9

Differential unit

8

Adjuster nut/ring

Assemble drive head

7

Bearing cap bolts

10

Ring threads

9

Differential unit

6

Split pins

12

Flange

11

Special tool pinion oil seal installer 090 589 30 59 00



Disassemble

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

1

Remove drive head unit from the vehicle.

AR35.31-Y-0520C

2

Lifting the differential unit using special tool lifting hook (1).

 Removal tool

*090589005900

3

Place the drive head in stand using special tool drive head overhaul stand (2), rotating bracket (3) and mounting bracket (4).

 Bracket

*090589393100

 Holding device

*090589196200

 Assembly stand

*090589009900

4

Position drive head unit on the overhaul stand as shown in the illustration.

5

Measure the crown wheel pinion backlash using magnetic stand and dial gauge (5).

AR35.30-Y-0475-02C

 Always check the backlash and note down the reading before dismantling the drive head unit. Always record tooth contact pattern at four points.

6

Check and record the tooth contact pattern.

AR35.30-Y-0475-02C

7

Remove the split pins (6) from the bearing adjuster nuts.

8

Loosen the both side bearing cap bolts (7).

9

Unscrew both side adjuster nut/ring (8) using special tool bearing adjuster.

 Adjustment tool

*090589172100

10

Remove the differential unit (9) from the drive head casing using suitable belt.


Care must be taken while removing the differential casing.
To ensure that the side bearing and outer race are not damaged.

11

Remove pinion housing.

AR35.30-Y-0469B

12

Disassemble pinion shaft.

AR35.30-Y-0459E

13

Disassemble crown wheel.

AR35.30-Y-0462E

Drive head inspection

14

Check the crown wheel and the pinion for damages on the teeth.

 Check for chipping of edges deep scoring, scuffing, excessive wear and improper teeth contact etc.

If necessary,



replace the crown wheel and pinion as a set.

15

Check the crown wheel mounting holes and mating threaded holes in the differential housing for any damage.

If necessary,



replace the crown wheel and pinion as a set.

16

Check the bearings of crown wheel and pinion.

 Check for any scoring, pitting, visible indentations and discoloration.

If necessary,



replace the bearing unit as a set.

17

Check differential housing inside for any abnormal wear on the thrust washer seating areas of the sun and star gears.

 Replace the either thrust washers or the housing based on extent of wear.

18

Check differential gears for any damages to the teeth.

 Check the internal splines of sun gear and star gear inner bore.

If necessary,



change the set of differential gear.

19

Check spider arms for any abnormal wear, scoring and discoloration.

If necessary,



change the set of differential gear.

20

Check adjusting ring threads and corresponding threads on the drive head of differential side bearings.

 Clean the threads and reuse.

If the damage is excessive,



replace drive head housing.

21

Check the bearing seating areas of pinion bearings and differential side bearings.

 Check for any rotation marks or any other damage in the drive head.

If necessary,



replace the drive head housing.

22

Check the drive head seating area over the rear axle and pinion housing for any damages.

 Rectify seating area on the rear axle or drive head as per the requirement.

23

Check the companion flange.

 Check for any damage at the splines as well deep scoring marks at the oil seal contact area.

If necessary,



replace companion flange.

Cleaning procedure

24

The differential carrier unit to be cleaned with cotton cloth.


Once removed from its housing, do not steam clean differential carrier unit.
As water can get trapped and lead to rust formation.

25

Disassemble the differential carrier unit completely and clean it with solvents.


Petrol is not an acceptable solvent.
Due to its extreme combustibility and this is unsafe in the workshop environment.

 There are many suitable commercial solvents available. (Kerosene and diesel fuel are also acceptable).

26

Dry parts immediately.

 Smear with oil then cover the components with polyethylene to avoid dust entry.



Assemble

27

Crown wheel and pinion replacement.

AR35.31-Y-0550-25E

28

Assemble pinion shaft.

AR35.30-Y-0459E

29

Install pinion housing.

AR35.30-Y-0469B

30

Assemble crown wheel.

AR35.30-Y-0462E

31

Check the pinion housing bearing pre-load.

AR35.30-Y-0458-06C

32

Install the entire differential unit (9) with crown wheel to the drive head housing and remove the belt.



BB00.40-P-0235-01A

 Ensure the crown wheel teeth and pinion teeth face each other.
Lubricate bearings during this assembly.

33

Apply oil to the differential side bearing adjusting rings threads (10) and install them.



BB00.40-P-0235-01A

 Ensure the bearing shells are properly seated.

34

Install differential side bearing cap bolts (7) and hand tighten the mounting bolts 4 numbers.

 Rotate the adjuster rings and ensure the free movement over the threads.

35

Inspect crown wheel to pinion backlash.

AR35.30-Y-0475-02C

36

Adjust tooth contact pattern.

AR35.30-Y-0475-02C

Assemble drive head

37

Fit new split pins (6) into the bearing caps/adjusting ring.

 Don't reuse the split pins to the bearing caps/adjusting ring.

38

Remove the old flange nut and flange from the pinion shaft.

39

Install new oil seal to pinion housing using special tool pinion oil seal installer (11) with flange and tightened the new pinion nut.


Don't reuse the pinion flange nut and pinion seal, replace with new one.
This may cause damage.

 Hold the flange (12) using special tool flange holder.

 Pulling device

*090589305900

40

Remove the drive head unit from overhaul stand.

AR35.31-Y-0520C

 Prepare the drive head for installation to rear axle.

 Drive head to axle housing

*BA35.30-Y-1004-06B

 DANA axle - Drive head disassembly and assembly procedure

Number

Designation

Rear axle 400.750 in model 831.001/002/005

BA35.30-Y-1004-06B

Drive head to axle housing

Nm

203.510.5