Remove and install drive pinion and ring gear with differential

AR35.30-D-4815A

Remove and install drive pinion and ring gear with differential

13.02.2020

Rear axle

741.130 in model 690.6, 904

Rear axle

741.131 in model 667

Rear axle

741.407 in model 901, 902

Rear axle

741.408 in model 690.6, 903

Rear axle

741.409 in model 690.6, 903

1

Collar nut

2

Bolts

3

Joint flange

4

Radial shaft sealing ring

5

Tapered roller bearing

6

Compressed ring

7

Drain screw

8

Shim

9

Tapered roller bearing

10

Drive pinion

11

Housing cover seal

12

Housing cover

13

Oil filler plug

14

Bolts

15

Bolts

16

Bearing bracket

17

Ring gear with differential

18

Spacer washers

Notes on installing a revised final drive ratio

Rear axle 741.130 in model 904.6
Rear axle 741.407 in model 901.6, 902.6
Rear axle 741.408 in model 903.6
Rear axle 741.409 in model 903.6

AH35.00-N-0001-01A



Remove

1

Detach complete wheels at rear axle

Rear axle 741.130 in model 690.6, 904
Rear axle 741.131 in model 667
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 690.6, 903
Rear axle 741.409 in model 690.6, 903

Rear axle 741.130 in model 690.6, 904
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 690.6, 903
Rear axle 741.409 in model 690.6, 903

AR40.10-D-1100A

2

Drain oil from rear axle

Rear axle 741.130 in model 690.6, 904
Rear axle 741.131 in model 667
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 690.6, 903
Rear axle 741.409 in model 690.6, 903



Rear axle 741.130 in model 904
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 903

AP35.00-D-3501B



Rear axle 741.130 in model 690.6
Rear axle 741.131 in model 667
Rear axle 741.408 in model 690.6
Rear axle 741.409 in model 903.663

AP35.00-D-3501A

3

Remove propeller shaft at joint flange (3)

4

Remove both rear axle shafts

Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 690.6, 903
Rear axle 741.409 in model 690.6, 903

AR35.30-D-0620D

Rear axle 741.130 in model 690.6, 904
Rear axle 741.131 in model 667

AR35.30-D-0620B

5

Remove housing cover (12) from rear axle housing

6

Remove differential from rear axle housing

AR35.30-D-4815-01A

 Spreader

*460589053100

7

Check tapered roller bearing of differential housing

If damage is present



Replace tapered roller bearing of differential housing.

8

Detach joint flange (3) at drive pinion (10)

AR35.30-D-4670-01A

 Retainer wrench

*717589003100

 Puller

*035589013300

9

Drive out drive pinion (10) out of rear axle housing and remove with compression ring (6)

AR35.30-D-4300-01A

 Puller

*001589193300

10

Check tapered roller bearing (9) of drive pinion (10)

If damage is present



Replace tapered roller bearing (9) of drive pinion (10).

11

Drive out tapered roller bearing (5) and radial shaft sealing ring (4)

 Drift

*343589031500

12

Drive out tapered roller bearing outer race of the tapered roller bearing (9) at the pinion end and remove with spacer washer (8)

 Rear axle 741.407 in model 901, 902
except code AE1 (Axle ratio i = 2.923)
Rear axle 741.408 in model 690.6, 903
except code AE1 (Axle ratio i = 2.923)
Rear axle 741.409 in model 690.6, 903
Thrust piece

*601589016300

 Rear axle 741.130 in model 690.6, 904
Rear axle 741.131 in model 667
Thrust piece

*601589106300



Install

13

Measure basic dimension at differential

Rear axle 741.130/131/407/408/409 except code A71 (Rear axle differential lock)

AR35.30-D-4815-02A

Notes on labeling rear axle gear set

Rear axle 741.131 in model 667
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 690.6, 903
Rear axle 741.409 in model 690.6, 903

AH35.30-N-0001-01A

Rear axle 741.130/131/407/408 with code A71 (Rear axle differential lock)

AR35.30-D-4815-02B

 Adjustment device

*601589002100

 Hinterachse 741.130/131/407/408 mit Code A71 (Differentialsperre Hinterachse)
Ring

*460589036300

14

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

AR35.30-D-4815-03A

Preload of differential bearing

*BE35.30-N-1002-01B

15

Install differential in rear axle housing

AR35.30-D-4815-04A

 Do not mount bearing bracket (16) yet or check gear backlash yet.

Rear axle differential gear backlash

*BE35.30-N-1005-01B

 Rear axle 741.130 in model 904.61/66
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 903.61/66/67
Rear axle 741.409 in model 690.6, 903Bearing bracket of differential housing to axle centerpiece

*BA35.30-N-1002-02A

 Dial indicator holder

*363589022100

 Dial gage

*001589532100

 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 with spacer washers (18) again

AR35.30-D-4815-01A

 Spreader

*460589053100

18

Measure difference dimension of drive pinion

AR35.30-D-4815-06A



BT35.30-D-0006-01A

 Measuring plate

*140589162300

 Measuring piece

*601589012300

 Dial gage

*001589532100

 Dial indicator holder

*363589022100

19

Measure basic dimension on rear axle housing and determine thickness of spacer disk (18) 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

 Ring

*460589036300

20

Installing drive pinion with bearing in rear axle housing

AR35.30-D-4815-09A

 Replace compression ring (6).

 Drift

*318589011500

 Support bridge

*601589026300

 Drift

*000589101500

 Drift

*312589051500

 Drift

*624589001500

21

Install new radial shaft sealing ring (4) at 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

Mount joint flange (3) at drive pinion

Rear axle 741.408 in model 690.6, 903
Rear axle 741.409 in model 690.6, 903

AR35.30-D-4670-03A

Rear axle 741.130 in model 690.6, 904
Rear axle 741.131 in model 667
Rear axle 741.407 in model 901, 902

AR35.30-D-4670-03B


The total friction moment must not be reached by loosening the collar nut (1). Do not exceed permissible total friction moment.
Otherwise, compression ring (6) must be replaced.

 Install new collar nut (1).

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.

 Adjustment device

*601589002100

 Dial gage

*001589532100

 Measuring piece

*601589012300

 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 741.130 in model 904.61/66
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 903.61/66/67
Rear axle 741.409 in model 690.6, 903Bearing bracket of differential housing to axle centerpiece

*BA35.30-N-1002-02A

Rear axle differential gear backlash

*BE35.30-N-1005-01B

 Spreader

*460589053100

 Torque meter

*001589492100

 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 (12) with new seal at rear axle housing

 Bolt, cover to rear axle housing

*BA35.25-N-1001-01A

28

Install both rear axle shafts

Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 690.6, 903
Rear axle 741.409 in model 690.6, 903

AR35.30-D-0620D

Rear axle 741.130 in model 690.6, 904
Rear axle 741.131 in model 667

AR35.30-D-0620B

29

Mount propeller shaft onto joint flange (3)

Topical note

Notes on installing propeller shaft

Rear axle 741.130 in model 690.6, 904
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 690.6, 903
Rear axle 741.409 in model 690.6, 903

AH41.10-N-0001-01A

 Models 690.6, 901, 902, 903, 904Bolt, rear propeller shaft to rear axle

*BA41.10-N-1002-01B

 Rear axle 741.131 in model 667Bolt, rear drive shaft to rear axle

*BA41.10-N-1002-01D

30

Pour in oil at rear axle

Rear axle 741.130 in model 690.6, 904
Rear axle 741.131 in model 667
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 690.6, 903
Rear axle 741.409 in model 690.6, 903



Rear axle 741.130 in model 904
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 903

AP35.00-D-3501B



Rear axle 741.130 in model 690.6
Rear axle 741.131 in model 667
Rear axle 741.408 in model 690.6
Rear axle 741.409 in model 690.6, 903.663

AP35.00-D-3501A

31

Attach complete wheels

Rear axle 741.130 in model 690.6, 904
Rear axle 741.131 in model 667
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 690.6, 903
Rear axle 741.409 in model 690.6, 903

Rear axle 741.130 in model 690.6, 904
Rear axle 741.407 in model 901, 902
Rear axle 741.408 in model 690.6, 903
Rear axle 741.409 in model 690.6, 903

AR40.10-D-1100A

 Rear axle 741.131 in model 667Wheel nut

*BA40.10-N-1001-01B

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.40/43

Rear axle 741.1

BE35.30-N-1001-01B

Friction torque of drive pinion bearing

with radial shaft sealing ring

Nm

2,5...3

2,5...3

without radial shaft sealing ring

Nm

1,65...3,74

1,65...3,74

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.40/43

Rear axle 741.1

BE35.30-N-1002-01B

Preload of differential bearing

mm

0,16

0,16

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.40/43

Rear axle 741.1

BE35.30-N-1003-01B

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

N

35...45

35...45

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.40/43

Rear axle 741.1

BE35.30-N-1004-01B

Specified basic dimension for rear axle housing

mm

66

66

Test and adjustment values for rear axle drive

Number

Designation

Rear axle 741.40/43

Rear axle 741.1

BE35.30-N-1005-01B

Rear axle differential gear backlash

mm

0,10...0,15

0,10...0,15

 Axle housing

Number

Designation

Rear axle 741.40/43

Rear axle 741.130/131

BA35.25-N-1001-01A

Bolt, cover to rear axle housing

M8

Stage 1

Nm

65

65

Stage 2

°

-

-

M10

Stage 1

Nm

-

-

Stage 2

°

-

-

 Axle drive

Number

Designation

Rear axle 741.130 in model 904.61/66, 909

Rear axle 741.40 (except 741.408)
Rear axle 741.408 in model 903.61/66/67, 909
Rear axle 741.43

BA35.30-N-1002-02A

Bearing bracket of differential housing to axle centerpiece

M10

Stage 1

Nm

70

70

Stage 2

°

-

-

M121.5

Stage 1

Nm

-

-

Stage 2

°

-

-

M162

Nm

-

-

 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 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

°

-

 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