Remove and install drive pinion and ring gear with differential

AR35.30-D-4815H

13.02.2020

Rear axle	741.412 in model 900.63
Rear axle	741.412/415 in model 906.11/13/21/23/61/63/71/73
Rear axle	741.413/414/416/420 in model 906.15/25/65
Rear axle	741.413/414/420 in model 900.65
Rear axle	741.428 in model 8AC906.133/631/633/635
	with code ZL3 (National version for Latin America)
Rear axle	741.429 in model 8AC906.153/155/655/657
	with code ZL3 (National version for Latin America)

Modification notes

28.10.2014	Work procedure adapted to modified repair method.
27.10.2014	Special tool 000 589 30 33 00 replaced by special tool 000 589 31 33 00.		AR35.31-D-0550-07S

Remove and install drive pinion and ring gear with differential

Shown on rear axle 741.415

1	Collar nut
2	Screw
3	Joint flange
4	Radial shaft sealing ring
5	Outer tapered roller bearing
6	Compressed ring
7	Drain screw
8	Spacer washer
9	Inner tapered roller bearing
10	Drive pinion
11	Seal
12	Housing cover
13	Oil filler plug
14	Screw
15	Screw
17	Differential
18	Spacer washer

D35.30-1157-06

 Danger	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Notes on installing a revised final drive ratio	Rear axle 741.412 in model 900.63 Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73 Rear axle 741.413/414/416/420 in model 906.15/25/65 Rear axle 741.413/414/420 in model 900.65 Rear axle 741.428 in model 8AC906.133/631/633/635 with code ZL3 (National version for Latin America) Rear axle 741.429 in model 8AC906.153/155/655/657 with code ZL3 (National version for Latin America)	AH35.00-N-0001-01A
	Remove
1	Drain oil from rear axle
		Rear axle 741.428 in model 8AC906.133/631/633/635 with code ZL3 (National version for Latin America) Rear axle 741.429 in model 8AC906.153/155/655/657 with code ZL3 (National version for Latin America)	AP35.00-A-3501B
		Rear axle 741.412 in model 900.63 Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73 Rear axle 741.413/414/416/420 in model 906.15/25/65 Rear axle 741.413/414/420 in model 900.65	AP35.00-D-3501A
2	Remove complete rear axle		AR35.10-D-0010I
3	Clear outside of rear axle housing
4	Fix rear axle in place on assembly device
5	Remove both rear axle shafts	Rear axle 741.412 in model 900.63 Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73 Rear axle 741.413/414/416/420 in model 906.15/25/65 Rear axle 741.413/414/420 in model 900.65 Rear axle 741.428 in model 8AC906.133/631/633/635 with code ZL3 (National version for Latin America) Rear axle 741.429 in model 8AC906.153/155/655/657 with code ZL3 (National version for Latin America)
		Rear axle 741.413/414/416/420 in model 906.155/655/657 with code ZL3 (National version for Latin America) Rear axle 741.413/414/416/420 in model 906 except code ZL3 (National version for Latin America) Rear axle 741.413/414/420 in model 900.65 Rear axle 741.429 in model 8AC906.153/155/655/657 with code ZL3 (National version for Latin America)	AR35.30-D-0620B
		Rear axle 741.412 in model 900.63 Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73 except code ZL3 (National version for Latin America) Rear axle 741.428 in model 8AC906.133/631/633/635 with code ZL3 (National version for Latin America)	AR35.30-D-0620H
6	Detach housing cover (12)
7	Remove crown wheel with differential (17)		AR35.30-D-4815-01H
		 Spreader	*741589036300
8	Check tapered roller bearing on differential	In event of wear or damage
		
		Replace tapered roller bearing on differential
		Detach tapered roller bearings from differential case	AR35.30-D-4301-01S
		Install tapered roller bearings on differential housing	AR35.30-D-4300-05A
		 Puller	*001589503300
		 Collet chuck	*463589023400
		 Thrust piece	*463589013400
9	Remove joint flange (3) at drive pinion (10)		AR35.30-D-4670-01A
		 Retainer wrench	*717589003100
		 Puller	*035589013300
10	Remove drive pinion (10) and compression ring (6)		AR35.31-D-0550-07S
		 Puller	*711589033300
		 Puller	*000589893300
		 Internal extractor	*000589313300
		 Counter stay	*000589343300
11	Detach inner tapered roller bearing (9) from drive pinion (10)		AR35.30-D-4300-01A
		 The inner tapered roller bearing (9) must be replaced.
		 Puller	*001589193300
	Install
12	Press inner tapered roller bearing (9) onto drive pinion (10)		AR35.30-D-4300-01A
		 Replace inner tapered roller bearing (9).
13	Measure basic dimension on differential (17)		AR35.30-D-4815-02H
	Notes on labeling rear axle gear set		AH35.30-N-0001-01A
		 Adjusting device	*906589012100
14	Determine thickness of shims (18)		AR35.30-D-4815-03A
		Preload of differential bearing	*BE35.30-N-1002-01B
15	Determine difference dimension of drive pinion (10)		AR35.30-D-4815-06H
	Drive pinion end face machining changed	Rear axle 741.412 in model 900.63 Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73 except code ZL3 (National version for Latin America) Rear axle 741.428 in model 8AC906.133/631/633/635 with code ZL3 (National version for Latin America)	BT35.30-D-0006-01A
		 Measuring plate	*140589162300
		 Adjusting device	*906589012100
		 Dial gage	*001589532100
		 Dial indicator holder	*363589022100
16	Measure basic dimension at rear axle housing and thickness of shim (8) for adjusting basic dimension		AR35.30-D-4815-07H
		Specified basic dimension for rear axle housing	*BE35.30-N-1004-01B
		 Adjusting device	*906589012100
		 Dial gage	*001589532100
17	Install drive pinion (10) and compression ring (6) with bearing into rear axle housing		AR35.30-D-4815-09H
		 Replace compression ring (6).
		 Drift	*711589011500
		 Insertion tool	*741589004300
		 Pressing-on tool	*741589016300
18	Check sealing surface of radial shaft sealing ring (4) in rear axle housing	If damage is present:
		
		Rework sealing surface in rear axle housing
19	Install new radial shaft sealing ring (4)	 Drift	*741589021500
20	Attach joint flange (3) at drive pinion (10)		AR35.30-D-4670-03B
		 Replace joint flange (3) and collar nut (1).
		Friction torque of drive pinion bearing	*BE35.30-N-1001-01B
		 Retainer wrench	*717589003100
		 Torque meter	*001589492100
		The total friction moment must not be reached by loosening the collar nut (1). If the permissible total friction moment is exceeded:
		
		Install drive pinion (10) again and replace compression ring (6).
21	Check basic dimension again at rear axle housing		AR35.30-D-4815-07H
		 The basic dimension engraved on the ring gear must be achieved.
		Specified basic dimension for rear axle housing	*BE35.30-N-1004-01B
		 Adjusting device	*906589012100
		 Dial gage	*001589532100
22	Secure collar nut (1)
23	Install ring gear with differential (17) in rear axle housing		AR35.30-D-4815-04H
		 Rear axle 741.412 in model 900.63 Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73 Rear axle 741.413/414/416/420 in model 906.15/25/65 Rear axle 741.413/414/420 in model 900.65 Rear axle 741.428 in model 8AC906.133/631/633/635 with code ZL3 (National version for Latin America) Rear axle 741.429 in model 8AC906.153/155/655/657 with code ZL3 (National version for Latin America)Bearing bracket of differential housing to axle centerpiece	*BA35.30-N-1002-02A
		Rear axle differential gear backlash	*BE35.30-N-1005-01B
		 Spreader	*741589036300
		 Dial gage	*001589532100
		 Dial indicator holder	*363589022100
24	Check contact pattern of ring gear and pinion		AR35.30-D-4815-10H
		Engineer's blue, 80 ml tube, BLUE, Diamant	*BR00.45-Z-1002-07A
		 Holding fixture	*741589026300
		If contact pattern is incorrect
		
		Perform necessary corrections with changed shims (8, 18).
25	Clean sealing surfaces on rear axle housing and housing cover (12)
26	Install housing cover (12) with new seal (11)	 Bolt, cover to rear axle housing	*BA35.25-N-1001-01A
27	Install both rear axle shafts	REAR AXLE all
		Rear axle 741.413/414/416/420 in model 906.155/655/657 with code ZL3 (National version for Latin America) Rear axle 741.413/414/416/420 in model 906 except code ZL3 (National version for Latin America) Rear axle 741.413/414/420 in model 900.65 Rear axle 741.429 in model 8AC906.153, 906.155/655/657 with code ZL3 (National version for Latin America)	AR35.30-D-0620B
		Rear axle 741.412 in model 900.63 Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73 except code ZL3 (National version for Latin America) Rear axle 741.428 in model 8AC906.133/631/633/635 with code ZL3 (National version for Latin America)	AR35.30-D-0620H
28	Detach rear axle from assembly device
29	Install rear axle		AR35.10-D-0010I
30	Pour in oil at rear axle
	Rear axle - oil change	Rear axle 741.428 in model 8AC906.133/631/633/635 with code ZL3 (National version for Latin America) Rear axle 741.429 in model 8AC906.153/155/655/657 with code ZL3 (National version for Latin America)	AP35.00-A-3501B
	Rear axle - oil change	Rear axle 741.412 in model 900.63 Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73 Rear axle 741.413/414/416/420 in model 906.15/25/65 Rear axle 741.413/414/420 in model 900.65	AP35.00-D-3501A
		 The rear-axle's correct oil filling capacity must be strictly observed. Otherwise the rear axle may be damaged.

Test and adjustment values for rear axle drive

Number	Designation			Rear axle 741.412/413/414/416/420/428/429	Rear axle 741.415
BE35.30-N-1001-01B	Friction torque of drive pinion bearing	with radial shaft sealing ring	Nm	4,1...4,5	4,1...4,5
		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 741.412/413/414/416/420/428/429	Rear axle 741.415
BE35.30-N-1002-01B	Preload of differential bearing	mm	0,28	0,20

Test and adjustment values for rear axle drive

Number	Designation			Rear axle 741.412/413/414/416/420/428/429	Rear axle 741.415
BE35.30-N-1004-01B	Specified basic dimension for rear axle housing		mm	74,5	66

Test and adjustment values for rear axle drive

Number	Designation		Rear axle 741.412/413/414/416/420/428/429	Rear axle 741.415
BE35.30-N-1005-01B	Rear axle differential gear backlash	mm	0,13...0,18	0,13...0,18

 Axle housing

Number	Designation				Rear axle 741.412 in model 900.63 Rear axle 741.412/415/428 in model 906	Rear axle 741.413/414/416/420/429 in model 906 Rear axle 741.413/414/420 in model 900
BA35.25-N-1001-01A	Bolt, cover to rear axle housing	M8	Stage 1	Nm	25	-
			Stage 2	°	60	-
		M10	Stage 1	Nm	-	35
			Stage 2	°	-	45

 Axle drive

Number	Designation				Rear axle 741.415 in model 906	Rear axle 741.412/413/414/416/420/428/429 in model 906 Rear axle 741.412/413/414/420 in model 900
BA35.30-N-1002-02A	Bearing bracket of differential housing to axle centerpiece	M10	Stage 1	Nm	30	-
			Stage 2	°	60	-
		M121.5	Stage 1	Nm	-	40
			Stage 2	°	-	60
		M162		Nm	-	-

000 589 31 33 00

Internal extractor

711 589 01 15 00

Drift

741 589 02 63 00

Holding fixture

741 589 02 15 00

Drift

741 589 03 63 00

Spreader

741 589 01 63 00

Pressing-on tool

000 589 89 33 00

Puller

463 589 02 34 00

Collet chuck

001 589 53 21 00

Dial gage

001 589 19 33 00

Puller

140 589 16 23 00

Measuring plate

741 589 00 43 00

Insertion tool

711 589 03 33 00

Puller

001 589 49 21 00

Torque meter

000 589 34 33 00

Counter stay

906 589 01 21 00

Adjusting device

463 589 01 34 00

Thrust piece

001 589 50 33 00

Puller

363 589 02 21 00

Dial indicator holder

035 589 01 33 00

Puller

717 589 00 31 00

Retainer wrench

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

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