Repairing Outer Multi-Disk Carrier of Front Axle Drive Train (AV)

Repairing Outer Multi-disk Carrier of Front Axle Drive Train (AV)

Preceding work:
Outer multi-disk carrier of front axle drive train (AV) removed (28-300, section C). C. Removal and Installation of Outer Multi-Disk Carrier of Front Axle Drive Train (AV)


A. Dismantling and Assembling





Remove snap ring (94). Remove multi-disk stack. Replace burnt disks.

Install final disk (98). Alternately install one inner multi-disk (96) and two outer multi-disks (97).
Note: Place new disks in ATF oil for approx. 1 hour prior to assembly.

Measure outer multi-disk carrier of front axle drive train (AV).


B. Checking Pre-load of Front Axle Drive Train Disk Spring and Adjusting, If Necessary.

Note: This check is only required after replacing the transfer case housing, the front axle drive train piston or thrust pad.




1st version: Transfer case no.1 to 13 710

1 The dimension "S1" is adjusted by inserting different shims (99).
Basic dimension: S1 = 0.9 mm
Shims are available in the following thicknesses 0.5; 0.6; 0.7; 0.8 and 0.9 mm.




2nd version: Transfer case no.13 711 to 26 616
The dimension "S1" is specified by the design. Adjustment via shims is not necessary.




3rd version: Transfer case no.26 617 -->

Calculate dimension "A1".

2 Determinethe dimension "C" between the end face of gear and sealing surface of the transfer case housing using measuring bridge 124 589 03 31 00 and depth gauge.




3 Determine the dimension "D" between the stop face of thrust bearing and sealing surface of the transfer case housing using measuring bridge 124 589 03 31 00 and depth gauge.

4 Calculate dimension "A1"
Calculation formula: A1 = C - D
Specified dimension: 19.5 - 20.1 mm
Example:
C = 88.4 mm
D = 68.4 mm
A1 = 88.4 - 68.4 mm = 20.0 mm




5 Determine thickness "S1" of shims.
Calculation formula: S1 = 21.8 - A1
Specified dimension: 1.6 - 2.3 mm
Note: The dimension 21.8 mm is specified by design.
Example:
A1 = 20.0 mm
S1 = 21.8 - 20.0 = 1.8 mm
Two shims (99) of 0.9 mm thickness are to be inserted.
Shims are available in the following thicknesses 0.5; 0.6; 0.7; 0.8 and 0.9 mm.




Parts note:
Only the outer multi-disk carrier of the front axle drive train with a flat surface is still delivered as a spare part. If this has to be replaced in a 1st or 2nd version of the transfer case, a 0.9 mm shim is to be inserted.


C. Checking Multi-disk Play of Front Axle Drive Train and Adjusting, If Necessary.




1 Install outer multi-disk carrier of front axle drive train in transfer case housing (28-300, section C).

2 Measure play "S2" between the final disk and inner multi-disk using a feeler gauge, while compressing the multi-disk stack (arrows).
Note:
Specified dimension up to transfer case no.26.616: 1.3 - 1.7 mm
Specified dimension as of transfer case no.26.617: 0.6 - 1.0 mm




3 Correction of loose play "S2" depending on the version of the outer multi-disk carrier (different groove width) via snap rings (94) and/or outer multi-disks (95).
Note: Snap rings of 1.8 mm to 3.6 mm are available in increments of 0.2 mm and outer multi-disks of 1.8, 2.0 and 2.2 mm.