33 10 010 Removing and installing/replacing rear differential

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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.

Fig 1: Identifying Jacking Point

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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 completing repair work, check OIL LEVEL in rear axle differential.

Necessary preliminary work:

Remove PROPELLER SHAFT ON FINAL DRIVE .
- 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!

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 2: Supporting Rear Axle Final Drive Using Special Tools (33 5 200)

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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 3: Identifying All-Round Slot Using Special Tool 33 5 120 And 33 5 125

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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 4: Pressing Left Output Shaft Using Special Tool (33 5 123) And (33 5 121)

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Release screws (1).

Tightening torque 33 17 1AZ .

Installation note:

Adhere to the 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 Screws

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Release nut and remove bolt (1).

Tightening torque 33 17 2AZ .

Installation note:

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

Fig 6: Identifying 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 7: Installing Lower 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 8: Identifying 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.

Press wheel carrier min. approx. 12 cm upwards.

Fig 9: Securing Special Tool (31 5 220) With Wheel Studs On Drive Flange

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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.

Fig 10: Removing Left Output Shaft

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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 11: Pressing Rear Axle Final Drive Using Special Tools

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

Fig 12: Identifying Disculpate, Circlip And Coat Highlighted Contact Surface

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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 13: Identifying Lug

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Drive output shaft into rear axle final drive using special tool 33 5 125 / 33 5 127 and a rubber mallet.

Fig 14: Installing Output Shaft Into Rear Axle Final Drive Using Special Tool (33 5 125) And (33 5 127)

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Assembly sequence:

Install rear axle final drive with workshop jack and special tool 33 5 200 in rear axle support
Insert bolts (1) (do not tighten down)
Insert bolt from rear and replace nut (2) (do not tighten down)
Release tensioning strap, 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 Nuts And Bolts
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After installation:

Check OIL LEVEL in the rear axle final drive, correct if necessary.