Remove/install differential assembly

AR35.30-B-0432XA

04.08.2020

Rear axle	772 in model 384.233
Rear axle	772 in model 384.311
Rear axle	772 in model 384.333
Rear axle	772.111 in model 979

Modification notes

03.06.2019	Carcaça central do eixo traseiro	BF35.10-B-1001-01B
03.06.2019	Differential oil	BF35.10-B-1001-01D
21.06.2019	Carcaça central do eixo traseiro	BF35.10-B-1001-01B
27.11.2019	Carcaça central do eixo traseiro	BF35.10-B-1001-01B

Rear axle RS21.230

1	Axle housing
2	Differential support housing
3	Differential assembly (ring gear, pinion, planetary case and 2nd speed reduction gear
4	Filler plug
5	Drain plug
6	Control cylinder
7	Differential carrier bolt

B35.30-0050-06

	Remove
1	Remove the wheels	Remove/install wheels .	AR40.10-B-1100B
2	Remove the filler plug (4) and drain plug (5), drain the rear axle oil	Lubricating oil for transfer case and drive axle, DB supply specification 6630.00 - SAE 85W90 and 90	*BR00.45-Z-1112-06A
		 Oil filling plug	*BA35.10-B-1001-03D
		 Oil drain plug	*BA35.10-B-1002-03D
		 On rear axle 772.100Differential oil	*BF35.10-B-1001-01D
		 On rear axle 772.111Center housing of the rear axle	*BF35.10-B-1001-01B
3	Remove the rear half-shafts	Rear axle 772.100	AR35.30-B-0620XA
		Rear axle 772.111	AR35.30-B-0620XB
4	Remove the 2nd speed (6) control cylinder	Rear axle 772.100
5	Displace the 2nd speed control fork in the direction indicated by the arrow (clockwise)	Rear axle 772.100
6	Insert an appropriate lifting device under the differential carrier and lift it slightly	 Do not lift the vehicle by the axle housing (1).
7	Remove the fastening bolts (7)
8	Remove the conical group
	Install
9	Apply a bead of silicone on the on the seating surface between the faces of the differential carrier housing (2) and of the axle housing (1)	 The surface must be clean and dry. The cord must have approximately a width of 3 mm and be put also around the threaded orifices.
		Neutral silicone	*BR00.45-Z-1110-01A
10	Displace the 2nd speed control fork in the direction indicated by the arrow (clockwise)	Rear axle 772.100
11	Lubricate the differential gears	.	AR35.30-B-0432-04XB
		 The lack of the initial lubrication can cause irreparable damages in the differential set.
12	Install guide pins at the axle bridge	Rear axle 772.100 and 772.111	AR35.30-B-0432-02XB
	Guide bolts for installing differential assembly	.	WF58.50-B-3530-06XA
		 This application aims at facilitating the installation of the tapered group in the axle's bridge.
13	Install the differential carrier and tighten the fastening bolts (7) alternately and in a crosswise pattern	 Apply sealing compound on the bolts thread.
		Terolan 307/II, Dichtin 51, epple 22 sealant	*BR00.45-Z-1018-01A
		 .Differential carrier mounting bolts on the shaft body	*BA35.31-B-1001-02B
14	Install the 2nd speed control cylinder and tighten the bolts	Rear axle 772.100
		 Apply silicone on the control cylinder seating surface.
		 Apply sealing compound on the threads.
		Terolan 307/II, Dichtin 51, epple 22 sealant	*BR00.45-Z-1018-01A
		Neutral silicone	*BR00.45-Z-1110-01A
		 .2nd gear actuator attachment	*BA35.31-B-1003-02B

 Rear axle.

Number	Designation		Rear axle 772.100	Rear axle 772.111
BA35.10-B-1001-03D	Oil filling plug	Nm	40	48

 Rear axle.

Number	Designation		Rear axle 772.100	Rear axle 772.111
BA35.10-B-1002-03D	Oil drain plug	Nm	40	48

 Differential box

Number	Designation		Rear axle 772.100	Rear axle 772.111
BA35.31-B-1001-02B	Differential carrier mounting bolts on the shaft body	Nm	270...330	110...150

 Differential box

Number	Designation		Rear axle 772.100	Rear axle 772.111
BA35.31-B-1003-02B	2nd gear actuator attachment	Nm	50...60	-

 Rear axle

Number	Designation			Rear axle 772.111
BF35.10-B-1001-01B	Center housing of the rear axle	Filling volume	Litros	6,8
		Oil class		MB 235.20

 Rear axle

Number	Designation			Rear axle 772.100
BF35.10-B-1001-01D	Differential oil	Filling volume	Litros	19,5
		Oil class		MB 235.20

Repair materials

Number	Designation	Order number
BR00.45-Z-1018-01A	Terolan 307/II, Dichtin 51, epple 22 sealant	Use corresponding commercially available repair materials.
BR00.45-Z-1110-01A	Neutral silicone	Dow Corning 768
BR00.45-Z-1112-06A	Lubricating oil for transfer case and drive axle, DB supply specification 6630.00 - SAE 85W90 and 90	Use corresponding commercially available repair materials.

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