33 10 010 Removing and installing/replacing rear differential: Notes

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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/re-installing the rear axle final drive, both SHAFT SEALS FOR THE DRIVE FLANGE and the circlip on both output shafts must be replaced!
After completing repair work, CHECK GEARBOX OIL LEVEL .

Necessary preliminary tasks:

Deactivate and drain AIR SPRING/SUSPENSION SYSTEM
Remove PROPELLER SHAFT .
- Disconnect propeller shaft at rear axle differential.
- Release center mount.
- Tie up propeller shaft to underbody.

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

IMPORTANT: The following jobs must be carried out in the specified sequence!

Release bolt (1) on left shock absorber.

Remove shock absorber from pivot arm.

Tightening torque 33 52 4AZ .

Fig 1: Identifying Bolt On Left Shock Absorber

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

Fig 2: Identifying Round Slot On Output Shaft

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Use special tool 33 5 120 to press (in jolts) left output shaft by approx. 5 cm out of the rear axle final drive unit. The thrust piece of the bolt 33 5 122 positioned against the rear axle final drive unit (see arrow in illustration).

Fig 3: Pressing-Out Left Output Shaft Using Special Tool 33 5 120

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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 with tensioning strap 33 5 206 to special tool 33 5 200 .

IMPORTANT: Tensioning strap 33 5 206 must be pass through between output shafts and rear axle final drive cover!

Fig 4: Positioning Special Tool 33 5 200 On Workshop Jack

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Release screws (1).

Installation note:

Adhere to the installation sequence at the end of the procedure 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 Screws

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Release nut and remove bolt (1).

Installation note:

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

Fig 6: Identifying Rear Differential 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 right drive flange.

Press right-hand wheel carrier max. approx. 10 cm upwards.

Fig 7: Securing Special 31 5 220 With Wheel Studs To Right Drive Flange

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

IMPORTANT: Risk of damage!
Output shafts must under no circumstances rest on pivot arms!

Fig 8: Positioning Special Tool 33 5 200 On Workshop Jack

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Press front of final drive unit to the right.

Feed out left output shaft forwards and tie up.

Swing rear axle final drive towards left side.

Fig 9: Pressing Front Of Final Drive Unit To Right

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Use special tool 33 5 120 to press (in jolts) right output shaft out of the rear axle final drive unit. Here, thrust piece of bolt 33 5 122 must rest on rear axle final drive.

Feed right output shaft out of rear axle final drive and tie up.

Remove rear axle final drive.

Fig 10: Pressing Right Output Shaft Out Of Rear Axle Final Drive Unit Using Special Tool 33 5 120

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Installation

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

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

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Insert right output shaft into rear axle final drive unit.

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

Fig 12: Identifying Protection Ring

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IMPORTANT: In order to ensure correct locking of the output shaft in the rear axle final drive, make sure when driving in the output shaft that the tensioning strap 33 5 206 is not located between the rear axle final drive and the dust plate!

Drive output shaft with special tool 33 5 125 and a rubber mallet into rear axle final drive.

Fig 13: Driving-In Output Shaft With Special Tool 33 5 125

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Press front of final drive unit to the right.

Working from the front, fit left output shaft into rear axle final drive unit.

Pull out assembly protection ring at lug until one of the two predetermined rupture points gives.

Drive output shaft with special tool 33 5 125 and a rubber mallet into rear axle final drive.

Fig 14: Driving-In Output Shaft With Special Tool 33 5 125

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Tightening sequence:

Press rear axle final drive upward with 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 tensioning strap and lower special tool 33 5 200 and move away.
Tighten down screws (1).
Tightening torque 33 17 1AZ .
Tighten nut (2).
Tightening torque 33 17 2AZ .

Fig 15: Identifying Rear Axle Final Drive Mounting Nuts And Screws
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After installation

Activate and fill AIR SPRING SYSTEM
Check OIL LEVEL IN THE REAR AXLE FINAL DRIVE , correct if necessary.

Replacement

Modify THREE-HOLE FLANGE .