Differential Case: Service and Repair

REMOVAL
1. Drain rear axle oil
2. Remove rear axle center assembly (50). Removal and Replacement





3. Clamp rear axle center assembly in assembly stand tool No. 129 589 00 31 00 (054) and secure with support parts, part 15 and 09 (054a and 054b), or equivalents
4. Remove end cover (54) discard bolts (56b)





5. Using removal and installation tool No. 116 589 01 62 00, or equivalent, pull off and discard circlip (30)
6. Pull out connecting flange (33 or 33a)





7. Using a suitable screwdriver, press off radial seal ring (32 or 32a)


INSTALLATION
- Install in reverse order, noting the following information:





- Coat the outside diameter and sealing lip of radial seal ring (32 or 32a) with hypoid or universal hypoid transmission fluid, then press into case using assembly mandrel tool No. 126 589 00 15 00 (049b), or equivalent
- Check contact surface for radial seal ring on connecting flange, if there are severe scores, replace connecting flange
- Replace circlip (30) using new component
- Check. adjust axial play of connecting flange as follows:





a. Ensure that the spacer (31b) is installed on the flange
b. Check axial play between the connecting flange and differential side gear, installing a thicker or thinner spacer (31b) if necessary.
c. The axial play must be within the specified tolerance range of 0.03-0.30 mm
- Spacers are available in thicknesses ranging from 0.7 mm to 1.5 mm in 0.05 mm graduations.
- Clean sealing surfaces for end cover and coat with Hylomar sealing compound part No. 000 989 25 20, or equivalent
- Install end cover using NEW collared bolts (56b), then tighten to: 50 Nm
- Install NEW rear axle breather and tighten to: 25 Nm
- Fill axle with: 1.1 liters of suitable rear axle fluid