Removing and installing/replacing rear axle differential

Special tools required:

33 5 206
33 5 200
33 5 120
2 360 787
2 240 465
0 496 862
33 5 124
33 5 122
2 360 944
2 240 464
2 406 774
33 5 125

WARNING: High-voltage system - danger to life

Observe SAFETY INFORMATION for working with electric vehicles.

WARNING: Rear axle differential must be lashed with tensioning strap 33 5 206 to prevent it from falling out when the output shafts are pressed off.

Attention!

When reinstalling the current rear axle differential, BOTH RADIAL SHAFT SEALS OF THE OUTPUT SHAFTS must be replaced!

The circlips on both output shafts must be replaced!

Necessary preliminary tasks:

Remove PROPELLER SHAFT FROM REAR AXLE DIFFERENTIAL .
- 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!

Loosen screw (1).

Detach the cable clip (2) from the rear axle differential.

Lay cable (3) to one side.

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Place the special tool 33 5 200 onto the universal 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.

Attention!

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

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Attention!

The following special tool must be inserted into the slot (1) of the output shaft on all sides.

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Left output shaft only:

Jerk the output shaft out of the rear axle differential using set of special tools 33 5 120 and the suitable special tool 2 360 787 , 2 240 465 , 0 496 862 or 33 5 124.

The thrust piece of the screw 33 5 122 must be in contact with the rear axle differential.

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Release screws (1).

Tightening torque 33 17 1AZ .

Installation note:

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

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Release nut (1) and push screw towards rear to the limit position.

Tightening torque 33 17 2AZ .

Installation note:

Replace nut.

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

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

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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.

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Right output shaft:

Jerk the output shaft out of the rear axle differential using set of special tools 33 5 120 and the suitable special tool 2 360 787 , 2 240 465 , 0 496 862 or 33 5 124.

The thrust piece of the screw 33 5 122 must be in contact with the rear axle differential.

Feed out output shaft and tie up.

Remove REAR AXLE FINAL DRIVE .

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Attention!

High installation forces indicate that the output shaft spline teeth are damaged or deformed!

Check gearing and replace components if damaged.

Check dust plate (1) for damage, replace if necessary.

Circlip (2) must be replaced!

Coat highlighted contact surface (3) of output shaft with approved FINAL DRIVE OIL .

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Installation note:

Insert output shaft into rear axle differential.

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

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Drive output shaft into the rear axle differential using suitable special tool 2 360 944, 2 240 464 , 2 406 774 or 33 5 125 and a rubber mallet.

Installation note:

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

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Assembly sequence:

Insert the rear axle differential 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).
Tightening torque 33 17 2AZ .

After installation:

Check OIL LEVEL IN THE REAR AXLE FINAL DRIVE , correct if necessary.

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