C. Dismantling and Assembling (Up to Transfer Case No. 26 617)

Repairing Multi-disk Stack of Center Differential Lock (ZS)

Preceding work:
Sun gear shaft removed (28-300, section A). A. Removal and Installation of Sun Gear Shaft

C. Dismantling and Assembling (up to transfer case no.26 617)

Multi-disk stack of center differential lock (ZS) with automatic adjustment

Special Tools:

Dismantling




1 Bend up all securing clips and carefully remove closing plate (103).




2 Remove wire circlip (102). Insert balls (104) and thrush washer (105).
Note: Observe installed position of thrust washer (105). One-piece contact surface points towards the axial bearing.




3 Mount assembly sleeve (016) and preload disk spring using the clamping device 201 589 00 63 00 or a hydraulic press.
Note: To preload the disk springs, clamp the shaft in a vise, push on sun gear shaft with center differential lock clutch and tighten tensioning nut using a box wrench WAF 32.

4 Unscrew adjusting nut (101). Remove circlip (87) from the groove using pliers 000 580 53 37 00 and push upwards.
Note: Adjusting nut with left-hand thread

5 Remove assembly sleeve (016).




6 Remove multi-disk stack (82, 83).




7 Remove inner multi-disk carrier (86) with balls (104) and thrust washer (105).




8 Mount assembly sleeve (016) and preload disk spring.

9 Remove circlip (87) from the groove using pliers and push upwards.

10 Remove assembly sleeve (016).




11 Remove pressure plate (93), disk spring (91) with spacer ring (92) and 2-piece circlip (89).


Assembly

12 Push on 2-piece cirdip (89), spacer ring (92), disk spring (91), thrust plate (93) and circlip (87).




13 Mount assembly sleeve (016) and preload disk spring.

14 Insert circlip (87) in the groove of the sun gear shaft using pliers.

15 Remove assembly sleeve (016).




16 Push on inner multi-disk carrier (86) and circlip (87) and insert balls (104) and thrust washer (105).




17 Mount assembly sleeve (016) and preload disk spring.

18 Mount circlip (87) in the groove of the sun gear shaft using pliers.

19 Remove assembly sleeve (016).




20 Mount outer multi-disks (83) and inner multi- disks (82) on the inner multi-disk carrier.
Note: Place new multi-disks in ATF oil for approx. 1 hour.




21 Insert final disk (100).
Note: Center multi-dislexactly on the splines of the inner multi-disk carrier.




22 Insert sun gear shaft complete in the locator 124 589 04 31 00, centering the multi-disk stack at the same time.

23 Place adjusting nut (101) on the inner multi-disk carrier (86).

24 Mount assembly sleeve and preload disk spring.

25 Screw on adjusting nut (101) until there is a distance of approx. 3 cm (A) between the center bore of the adjusting nut (101) and the center bore of the final disk (100).
Note: Only assemble adjusting nut (101) loosely
The dimension (A) can be corrected by relocating the final disk (100).

26 Remove assembly sleeve.




27 Insert the wire cirdip (102) 50 that this contacts the outer circumference of the final disk (100) for atleast 90°, but a maximum of 270°.
Checking automatic adjustment
Mount assembly sleeve (16) and preload disk spring, observing whether the wire circlip (102) adjusts the adjusting nut (101) automatically due to its spring force.
Note: If the adjusting nut (101) has not adjusted itself when the load on the disk spring (91) is relieved, the center differential lock is excessively preloaded or a mistake was made during assembly. Dismantle the sun gear again and rebuild from item 12.




28 Mount closing plate (103) and carefully bend over all securing clips.
Note: When bending over the securing clips, ensure that no outer multi-disk is damaged.