Repairing differential - RA3500HMV0560X(35-560)

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Preceding work :

Removing and installing rear axle center piece (35-520)

Dismantling and assembling rear axle center piece, adjusting crown wheel/pinion (35-550)

Operation no. of operation texts and work units or standard texts and flat rates :

35-0815.

Fig 1: Identifying Differential Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Differential housing (12)	Clamp in vice, remove from vice.
	Clamp 201 589 02 31 00.
Dowel sleeve (19)	Drive out, drive in, replace.
Differential pin (16)	Press out, press in, remove.
	Drive out differential pin using drift 126 589 02 25 00.
Differential bevel gears (15), rear axle shaft gears (17), thrust washers (18) and spherical washers (14)	Crank out, crank in, remove (paragraphs 4-5 and 7-8). When assembling, center rear axle shaft gears and thrust washers with alignment tool 116 589 18 61 00.
	Center bevel differential gears and spherical washers with alignment tool 126 589 02 15 00. Check friction torque . Nominal value 40-90 Nm (paragraph 9).
Check	All parts to see if they can be reinstalled.

ADJUSTMENT OF DIFFERENTIAL GEARS

Friction torque when full differential assembly slips

40-90 Nm

DIFFERENTIAL HOUSING

Permissible radial run-out of differential housing at crown wheel location			0.02 mm
Permissible lateral run-out of differential housing at flange surface for crown wheel			0.02 mm
Thrust washer on rear axle shaft gear	Gauge	Crown wheel dia.210 mm	1.3 up to 1.7 mm
Thrust washer on rear axle shaft gear	Graduation		0.05 to 0.05 mm
Dowel sleeve		Crown wheel dia.210 mm	6X45 mm

Special tools

Fig 2: Identifying Special Tool (201 589 02 31 00 35)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Special Tool (126 589 02 15 00 33 35)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Special Tool (116 589 18 61 00 35)

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Fig 5: Identifying Special Tool (001 589 66 21 00 00)

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Dismantling

Fasten differential housing onto clamp (012) 201 589 02 31 00 and clamp in a vice.

Fig 6: Identifying Differential Housing
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Drive dowel sleeve (19) for differential pin (16) out of differential housing (12a) using a suitable drift.
Drive differential pin (16) out of differential housing using drift.
Drift 126 589 02 15 00

Fig 7: Identifying Dowel Sleeve, Differential Pin, Housing, Differential Bevel Gears And Thrust Washers
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Crank out differential bevel gears (15) and thrust washers (14) using alignment tool (017) 116 589 18 61 00, and remove.

Fig 8: Identifying Alignment Tool
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Remove rear axle shaft gears (17) with thrust washers from differential housing.

Fig 9: Identifying Rear Axle Shaft Gears
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Check all parts to see whether they can be reinstalled. Always replace differential bevel gears, thrust washers and spherical washers that have overheated or show signs of scoring.
Assembling
Install left-hand rear axle shaft gear (17, on crown wheel side) in differential housing with previously removed, approx. 0.2 mm thick thrust washer and center using alignment tool (017) 126 589 18 61 00.

Fig 10: Identifying Rear Axle Shaft Gears And Alignment Tool
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fit both differential bevel gears (15) and center using alignment tool (015) 126 589 02 15 00.
Check friction torque.
NOTE: Select the gauge of the thrust washers for the rear axle shaft gears so that the friction torque on each side is approx. 20 -30 Nm .

Fig 11: Identifying Differential Bevel Gears And Alignment Tool
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Repeat the instructions in paragraphs 7 to 9 with the right-hand rear axle shaft gear.

Fig 12: Identifying Rear Axle Shaft Gears
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Coat thrust washers (18) on both sides with molycote grease and place on rear axle shaft gear.
Install both rear axle shaft gears (17) in differential housing and center using alignment tool (017) 116 589 18 61 00.

Fig 13: Identifying Thrust Washers And Alignment Tool
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Install both differential bevel gears (15) together with spherical washers (14) in differential housing and crank in using alignment tool (017).

Fig 14: Identifying Differential Bevel Gears And Alignment Tool
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
In place of the differential pin, push alignment tool (015) 126 589 02 15 00 into differential housing to center differential bevel gears and spherical washers.

Fig 15: Identifying Alignment Tool
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Check total drive torque.
NOTE: The friction torque should be 40 -90 Nm , although if impeded the measured value can rise to as much as 100 Nm.

Fig 16: Identifying Torque Wrench
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Drive in differential pin (16) and remove alignment tool (015).

Fig 17: Identifying Differential Pin And Alignment Tool
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When driving in the differential pin (16), watch the bore for the dowel sleeve. Use a suitable tool to check that the bores are correctly aligned (dashed line) and correct if necessary.

Fig 18: Identifying Differential Pin
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Press new dowel sleeve (19) into differential housing using a suitable drift.

Fig 19: Identifying Dowel Sleeve
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Press in dowel sleeve approx. 53.5 mm, measured from the end face.
Remove differential housing from clamp and vice.

Fig 20: Identifying Dowel Sleeve Pressing Dimension
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.