Remove/install differential assembly

AR35.30-P-0432GG

04.09.2018

Model	460
Model	461 (except 461.331)
Model	463 (except 463.270/271)
	up to model year 2013

1	Cover
2	Bearing bracket
3	Differential assembly
4	Shims
5	Bearing outer races
6	Seal

P35.30-2075-11

	Remove
1	Drain oil	 Remove oil drain screw.
2	Remove cover (1)
3	Remove both rear axle shafts	On rear axles with disk brakes	AR35.30-P-0620F
		On rear axles with drum brakes, except on rear axle 741.171/52/53	AR35.30-P-0620G
		On rear axle 741.171/52/53 with drum brakes	AR35.30-P-0620GL
4	Remove bearing bracket (2)	 Mark the installation position of the bearing brackets (2).
5	Mark shims (4) and bearing outer races (5)	 Mark installation position.
6	Remove differential assembly (3)	 Mount spreader onto the axle housing and spread until the differential assembly (3) can be removed.
		 Spreader	*460589053100
	Clean
7	Clean parts	Cold degreasing agent/cold cleaning solvent HAKU 1025-920	*BR00.45-Z-1051-04A
	Check
8	Inspect parts and replace if necessary	 Dismantle differential assembly (3) if necessary and reassemble:

		
		Disassemble, assemble differential assembly
			AR35.30-P-0433GG
	Install
9	Determine thickness of shims (4) for adjusting rear axle housing	Only if parts of the differential assembly (3) have been replaced.
		Model 460 Model 461 (except 461.331) Model 463 (except 463.270/271) up to model year 2013/Facelift 2012	AR35.30-P-4815-03F
		 In this case the pretension of the tapered roller bearing has to be determined again.
		 Ring	*460589036300
		 Adjustment device	*601589002100
10	Remove ring gear from differential	Only if parts of the differential assembly (3) have been replaced.
		 The ring gear has to be removed in order to measure the friction torque of the tapered roller bearing:

		
		Disassemble, assemble differential assembly
			AR35.30-P-0433GG
11	Install differential assembly (3)	Only if parts of the differential assembly (3) have been replaced.
		 Mount spreader and spread axle housing until the differential assembly (3) can be inserted.
		 Spreader	*460589053100
12	Align bearing outer races (5) and bearing rollers	 To do so, turn the differential several times while simultaneously applying settling blows to the differential using a plastic mallet.
13	Checking friction torque of tapered roller bearings	Only if parts of the differential assembly (3) have been replaced.
		Model 460 Model 461 (except 461.331) Model 463 (except 463.270/271) up to model year 2013/Facelift 2012	AR35.30-P-0470-04GH
		Ring gear friction torque (preload)Ring gear friction torque (preload)	*BE33.30-P-1002-01A
14	Remove differential assembly (3)	Only for new differential housing or new tapered roller bearings.
		 Mount spreader onto the axle housing and spread until the differential assembly (3) can be removed.
		 Spreader	*460589053100
15	Mount ring gear to differential	 Only when parts of the differential assembly (3) have been replaced:

		
		Disassemble, assemble differential assembly
			AR35.30-P-0433GG
16	Install differential assembly (3)	 Pay attention to the markings on the shims (4) and bearing outer races (5). Mount spreader and spread axle housing until the differential assembly (3) can be inserted. Align the bearing outer races (5) and bearing rollers by applying settling blows to the ring gear; turn the ring gear several times when doing so.
		 Spreader	*460589053100
17	Install bearing bracket (2)	 Pay attention to marking.
		 Bolt, bearing bracket to axle housingBolt, bearing bracket to differential housing	*BA35.30-P-1001-05A
18	Measure gear backlash and adjust if necessary	Model 460 Model 461 (except 461.331) Model 463 (except 463.270/271) up to model year 2013/Facelift 2012	AR35.30-P-0475-03GH
		Gear backlashGear backlash	*BE35.30-P-1001-05A
		 Dial gage	*001589532100
		 Dial indicator holder	*363589022100
19	Check contact pattern of ring gear and drive pinion		AR35.30-P-0475-02F
		Engineer's blue, 80 ml tube, BLUE, Diamant	*BR00.45-Z-1002-07A
		 Holding device	*601589014000
20	Install rear axle shafts	On rear axles with disk brakes	AR35.30-P-0620F
		On rear axles with drum brakes, except on rear axle 741.171/52/53	AR35.30-P-0620G
		On rear axle 741.171/52/53 with drum brakes	AR35.30-P-0620GL
21	Install cover (1)	 Replace the seal (6); do not use any sealant.
		 Bolt, end cover to axle housingScrew/bolt, end cover to rear axle housing	*BA35.30-P-1003-02A
22	Screw in oil drain screw	 Oil drain screw to axle housingDrain screw at rear axle housing	*BA35.30-P-1001-02A
23	Remove oil filler screw and fill with oil	 MODEL 460, 461 (except 461.331), MODEL 463 (except 463.270/271) up to model year 2013Hypoid gear oil	*BF35.10-P-1001-01A
24	Screw in oil filler plug	 Oil filler screw to axle housingOil filler screw at rear axle housing	*BA35.30-P-1002-02A

Check values for ring gear with differential

Number	Designation		Model 460, 461, 463
BE33.30-P-1002-01A	Ring gear friction torque (preload)	Kg	40,5

Test values for ring gear with differential

Number	Designation		Model 460, 461, 463
BE35.30-P-1001-05A	Gear backlash	mm	0,1-0,15

 Rear axle axle drive

Number	Designation			Model 460	Model 461
BA35.30-P-1001-02A	Drain screw at rear axle housing	Stage 1	Nm	90	90
		Stage 2	°	-	-

 Rear axle axle drive

Number	Designation			Model 463 up to model year 2019	Model 463 as of model year 2019
BA35.30-P-1001-02A	Drain screw at rear axle housing	Stage 1	Nm	90	60
		Stage 2	°	-	90

 Ring gear with differential

Number	Designation			Model 460, 461 Model 463 up to model year 2019	Model 463 as of model year 2019
BA35.30-P-1001-05A	Bolt, bearing bracket to differential housing	Stage 1	Nm	75	30
		Stage 2	°	-	60

 Rear axle axle drive

Number	Designation		Model 460	Model 461
BA35.30-P-1002-02A	Oil filler screw at rear axle housing	Nm	90	90

 Rear axle axle drive

Number	Designation		Model 463 up to model year 2019	Model 463 as of model year 2019
BA35.30-P-1002-02A	Oil filler screw at rear axle housing	Nm	90	90

 Rear axle axle drive

Number	Designation			Model 460	Model 461
BA35.30-P-1003-02A	Screw/bolt, end cover to rear axle housing	Stage 1	Nm	65	65
		Stage 2	°	-	-

 Rear axle axle drive

Number	Designation			Model 463 up to model year 2019	Model 463 as of model year 2019
BA35.30-P-1003-02A	Screw/bolt, end cover to rear axle housing	Stage 1	Nm	65	25
		Stage 2	°	-	60

 Rear axle

Number	Designation			Model 460 up to 5/31/82 with rear axle 741.5 up to 5/31/82 Model 461 (except 461.339/392) up to 5/31/82 with rear axle 741.5 (except 741.534) up to 5/31/82	Model 460 as of 6/1/82 with rear axle 741.5 as of 6/1/82 Model 461 (except 461.339/392) as of 6/1/82 with rear axle 741.5 (except 741.534) as of 6/1/82
BF35.10-P-1001-01A	Hypoid gear oil	Filling capacity	Liter	1,6	1,8
		Sheet		BB00.40-P-0235-00A	BB00.40-P-0235-00A

 Rear axle

Number	Designation			Model 461.339 with code ZD4 (Vehicle for non-civilian operations)	Model 461 with rear axle 741.1 Model 461 with rear axle 741.680 Model 461 with rear axle 742.6
BF35.10-P-1001-01A	Hypoid gear oil	Filling capacity	Liter	1,8	1,8
		Sheet		BB00.40-P-0235-61A	BB00.40-P-0235-00A

 Rear axle

Number	Designation			Model 461 with rear axle 741.690/691/692	Model 461.392 with rear axle 741.534, through-drive axle
BF35.10-P-1001-01A	Hypoid gear oil	Filling capacity	Liter	2,0	3,6
		Sheet		BB00.40-P-0235-00A	BB00.40-P-0235-00A

 Rear axle

Number	Designation			Model 463 (except 463.234/243/246/255/260/261/270/271/272/273/274/275/276/277/349)	Model 463.234/255
BF35.10-P-1001-01A	Hypoid gear oil	Filling capacity	Liter	1,8	1,8
		Sheet		BB00.40-P-0235-00A	BB00.40-P-0235-00A

 Rear axle

Number	Designation			Model 463.243/246/270/271/272/273/275
BF35.10-P-1001-01A	Hypoid gear oil	Filling capacity	Liter	1,8
		Sheet		BB00.40-P-0235-61A

601 589 01 40 00

Holding device

001 589 53 21 00

Dial gage

460 589 05 31 00

Spreader

363 589 02 21 00

Dial indicator holder

601 589 00 21 00

Adjustment device

460 589 03 63 00

Ring

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-1051-04A	Cold degreasing agent/cold cleaning solvent HAKU 1025-920	Chemische Werke Kluthe GmbH Gottlieb-Daimler-Str. 12 69115 Heidelberg Germany Tel. +49 6221 5301-0 Fax +49 6221 5301-176 http://kluthe.com

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