33 10 010 Removing and installing/replacing rear differential

Special tools required:

WARNING: Danger of injury!
Rear axle final drive must be lashed with tensioning strap 33 5 206 to prevent it falling out when the output shafts are forced off.

IMPORTANT: When removing/reinstalling the rear axle final drive, both OUTPUT SHAFT RADIAL SHAFT SEALS and the circlip on both output shafts must be replaced.
After completion of repair work, check oil level in rear axle differential. See CHECKING/TOPPING UP OIL LEVEL IN REAR DIFFERENTIAL

Necessary preliminary tasks:

Remove PROPELLER SHAFT on rear axle final drive.
- Disconnect propeller shaft at rear axle differential.
- Release center mount.
- Tie up propeller shaft to underbody.

NOTE: Bending the propeller shaft by an excessive angle can cause premature damage to the joint/propeller shaft!

Position special tool 33 5 200 on workshop jack.

Support rear axle final drive 33 5 200 with special tool.

Lash rear axle final drive unit to special tool 33 5 200 with tightening strap 33 5 206 .

IMPORTANT: Securing strap 33 5 206 must be passed through between output shafts and rear axle final drive cover.

Fig 1: Lashing Rear Axle Final Drive With Special Tools (33 5 200) And (33 5 206)

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IMPORTANT: Special tools 33 5 120 and 33 5 125 must be inserted in all-round slot (1) on output shaft!

Fig 2: Identifying Rear Differential All Round Slot

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Press only left output shaft out of rear axle final drive with jerking and jolting motions using special tool 33 5 123 , 33 5 121 , 33 5 124 /33 5 126 .

Here, synchronizing key of bolt 33 5 122 must rest on rear axle final drive.

Fig 3: Pressing Left Output Shaft Using Special Tools

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Release screws (1).

Tightening torque 33 17 1AZ

Installation note:

Adhere to the specified installation sequence in order to prevent distortion of the rear axle final drive during installation and thereby avoid potential complaints about noise.

Fig 4: Identifying Rear Differential Screws

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Release nut and remove bolt (1).

Tightening torque 33 17 2AZ .

Installation note:

Adhere to the specified installation sequence in order to prevent distortion of the rear axle final drive during installation and thereby avoid potential complaints about noise.

Fig 5: Identifying Rear Differential Bolt

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Lower rear axle final drive with special tool 33 5 200 .

IMPORTANT: Risk of damage!
Output shafts must not under any circumstances rest on swinging arms.

Fig 6: Lowering Rear Axle Final Drive Using Special Tool (33 5 200)

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Release bolt (1) on left spring strut.

Remove spring strut from wheel carrier.

Tightening torque 33 52 3AZ .

Fig 7: Identifying Left Spring Strut Bolt

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IMPORTANT: Risk of damage!
Output shafts must not under any circumstances rest on swinging arms.

Secure special tool 31 5 220 with wheel studs to left drive flange.

Fig 8: Securing Special Tool (31 5 220) With Left Drive Flange Wheel Studs

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Press wheel carrier min. approx. 12 cm upwards.

Press (tilt) rear axle final drive on right upwards.

Feed out left output shaft in downward direction and tie up.

Swing rear axle final drive towards left side.

Fig 9: Identifying Rear Axle Final Drive

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Press right output shaft out of rear axle final drive with jerking and jolting motions using special tool 33 5 123 , 33 5 121 , 33 5 124 /33 5 126 . Here, synchronizing key of bolt 33 5 122 must rest on rear axle final drive.

Feed out output shaft and tie up.

Remove rear axle final drive.

Fig 10: Pressing Rear Axle Final Drive Right Output Shaft Using Special Tools

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IMPORTANT: High installation forces indicate that the output shaft spline teeth are damaged or deformed!
Check splines and replaced parts if damaged.
Check dust plate (1) for damage, replace if necessary.
Replace circlip (2).
Coat highlighted contact surface (3) of output shaft with APPROVED OIL .

Fig 11: Identifying Output Shaft Contact Surface, Circlip And Dust Plate

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Installation note:

Insert output shaft into rear axle final drive.

Pull out assembly protection ring at lug (1) until one of the two predetermined breaking points gives.

Fig 12: Identifying Rear Differential Assembly Protection Lug

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Drive output shaft with special tool 33 5 125 /33 5 127 and a rubber mallet into rear axle differential.

Installation note:

The output shafts must audibly snap in place on the rear axle differential.

Fig 13: Driving Output Shaft Using Special Tools And Rubber Mallet

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Assembly sequence:

Insert the rear axle final drive into the rear axle support using the workshop jack and special tool 33 5 200 .
Insert screws (1) (do not tighten).
Insert bolt from rear and replace nut (2) (do not tighten down).
Release securing strap, lower special tool 33 5 200 and move it away.
Tighten down screws (1).
Tightening torque 33 17 1AZ
Tighten nut (2).

Fig 14: Identifying Rear Axle Final Drive Screws And Nut

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Tightening torque 33 17 2AZ

After installation:

Check oil level in the rear axle final drive, correct if necessary. See CHECKING/TOPPING UP OIL LEVEL IN REAR DIFFERENTIAL .