33 10 016 Removing and installing/replacing rear axle differential (220M) (M5)

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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/reinstalling the rear axle differential, both RADIAL SHAFT SEALS FOR THE DRIVE FLANGE and the circlip on both output shafts must be renewed!
After completion of repair work, CHECK OIL LEVEL IN REAR AXLE DIFFERENTIAL !
Use only the approved transmission oil. Refer to OPERATING FLUIDS .
Failure to comply with this instruction will result in serious damage to the rear axle differential.

Necessary preliminary tasks:

Remove EXHAUST SYSTEM .
REMOVE both rear wheels.
Remove rear TRAILING LINKS .
F12: remove support.
Partially remove PROPELLER SHAFT .
- 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!

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

Disconnect the plug connection (3) from the temperature sensor.

Release the cable clip (2) of the sensor cable (1) from the oil sump.

Fig 1: Identifying Plug Connection, Sensor Cable And Clip

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Disconnect the plug connection (1) from the servomotor of the rear axle differential (2).

Fig 2: Identifying Plug Connection And Rear Axle Differential

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Release screw (1) from ground strap (2).

Fig 3: Identifying Ground Strap And Screw

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Release bolt (1) on left (2) shock absorber.

Tightening torque 33 52 3AZ .

Release shock absorber (2) from wheel carrier (3).

Fig 4: Identifying Shock Absorber, Wheel Carrier And Bolt

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Special tools 33 5 120 and 33 5 126 must be inserted in all-round slot (1) on output shaft!

Fig 5: Identifying Round Slot On Output Shaft

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Press out left output shaft approx. 5 cm out of rear axle differential with jerky movements using special tool 33 5 120 with shaped element 33 5 126 .

The thrust piece of the bolt 33 5 122 positioned against the rear axle final drive unit (see arrow).

IMPORTANT: Risk of damage!
Do not support thrust piece of screw 33 5 122 at oil sump.

Fig 6: Identifying Special Tool (33 5 120)

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23 4 050 Position special tool on workshop jack. 00 2 030

23 4 050 Support rear axle final drive unit with special tool

Secure rear axle differential to special tool 23 4 050 with tensioning straps (1).

Fig 7: Identifying Special Tools (23 4 050)

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Unscrew nuts (1).

Remove the screws and the tuned mass damper weight (2).

Installation note:

Renew screws and nuts (1).

Adhere to the assembly sequence at the end of the information in order to prevent distortion of the rear axle differential during installation and thereby avoid potential complaints about noise.

Fig 8: Identifying Front Adapter Vibration Absorber And Screw

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Slacken nut (1).

Remove screw.

Installation note:

Replace nut (1).

Adhere to the assembly sequence at the end of the information in order to prevent distortion of the rear axle differential during installation and thereby avoid potential complaints about noise.

Fig 9: Identifying Nut & Screw

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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 10: Identifying Special Tool (31 5 220)

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Lower rear axle final drive with special tools 33 4 050 and 00 2 030 .

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

Fig 11: Identifying Special Tools (33 4 050 And 00 2 030)

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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 12: Pressing Front Of Final Drive Unit To Right

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Press out right output shaft out of rear axle differential with jerky movements using special tool 33 5 120 and shaped element 33 5 126 .

Here, thrust piece of bolt 33 5 122 must rest on rear axle final drive.

IMPORTANT: Risk of damage!
Do not support thrust piece of screw 33 5 122 at oil sump.

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

Remove rear axle final drive.

Fig 13: Pulling Out Output Shaft Of Rear Axle

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Assembly:

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. Refer to OPERATING FLUIDS .
High installation forces indicate that the output shaft spline teeth are damaged or deformed!
Check splines and replaced parts if damaged.

Fig 14: Identifying Dust Plate, Circlip And Contact Surface

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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 15: Identifying Protection Ring At Lug

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Special tool 33 5 127 must be fitted in all-round slot on output shaft.

Fig 16: Identifying Round Slot Area On Output Shaft

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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 is not located between the rear axle final drive and the dust plate!

Drive output shaft with special tool 33 5 127 and a rubber mallet into rear axle final drive.

Fig 17: Identifying Special Tool (33 5 127)

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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 5 127 and a rubber mallet into rear axle final drive.

Fig 18: Driving Output Shaft And Rubber Mallet Into Rear Axle Final Drive

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Tightening sequence:

Press rear axle differential (2) towards top with workshop jack and special tool 23 4 0150.
Screw in screw and new nut (3) (do not apply tightening force).
Screw in new screws with absorber weight and new nuts (1) (do not apply tightening force).
Release tensioning strap and lower special tool 23 4 150 and move away.
Apply tightening force to screws and nuts (1).
Tightening torque 33 17 1AZ .
Apply tightening force to screw and nut (3).

Fig 19: Identifying Rear Axle Differential Screw 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.
Replacement: Perform START-UP .