Differential Gear, Replacement

Differential gear, replacement

To remove
1. Remove the gearbox. See Gearbox assembly.
2. Remove the gearcase. See Gearcase, seal.





3. Remove the drive shaft, the lower main shaft and gear lever shaft, 1st/2nd - 5th/6th. Remove the shafts together.





4. Remove the upper main shaft with gear lever shaft 3rd/4th/reverse gear.
5. Remove the differential gear.





6. Remove the conical roller bearing inner ring on the gearcase side. Clamp the differential gear in a vice with protective jaws. Pull off with KM-161-10, KM-161 2 and KM-403 or 87 92 343 Puller, differential bearing.
7. Remove the conical roller bearing inner ring from the clutch housing side. Clamp the differential gear in a vice with protective jaws. Pull off with KM-161-10, KM 161-2 and KM-403 or 87 92 343 Puller, differential bearing.





8. Remove the conical roller bearing outer ring from the clutch housing side. Note the thickness of the spacer. Pull out with DT-46753, DT-46751 and KM-328-B or 87 91 683 Puller and 87 91 675 Puller





9. Remove the conical roller bearing outer ring from the gearcase. Pull out with DT 46753, DT-46751 and KM-328-B or 87 91 683 Puller and 87 91 675 Puller .
10. Clean the sealing surfaces.

To fit








1. Fit the conical roller bearing outer ring in the clutch housing side. Press in with DT-46757 (87 93 044 Fitting tool, to fit, differential bearing race.)and KM-523-1 ( 87 93 077 Centring mandrel, handle).





2. Fit the conical bearing inner ring in the gearcase side. Press on with DT-46759 on the differential gear.





3. Fit the conical bearing inner ring in the clutch housing side. Press on with DT 46759 on the differential gear.





4. Fit the conical roller bearing outer ring for the differential gear in the gearcase. Fit in the old shims or shims of the same thickness. Press in the outer ring for the conical roller bearing with DT-46757 (87 93 044 Fitting tool, to fit, differential bearing race. ) and KM-523-1 (87 93 077 Centring mandrel, handle ).
5. Fit the differential gear.





6. Measure the bearing play in the differential gear. Position the gearcase on the clutch housing. Tighten the gearcase with 6 bolts. Fit MKM-536-A or 87 92 483 Torque wrench with DT-46758 or suitable extension and with cross-slotted socket (size 4). Test tighten the differential gear several times. Measure the friction torque with MKM-536-A - reference value: 1.2 to 1.5 Nm. If the measurement value is outside the tolerance the bearing play must be set.
Tightening torque, bolts, gearcase 25 Nm (18 ft. lbs.)
7. Remove the gearcase 6 bolts.
8. Set the bearing play for the differential gear. Repeat this torque until the bearing play is within the reference value. If the friction torque is outside of the tolerance, set the bearing play in accordance with the following:
9. Remove the outer ring for the conical roller bearing in the gearbox side. Pull out with DT-46753, DT-46751 and KM-328-B or 87 91 683 Puller and 87 91 675 Puller .
10. Fit the outer ring for the conical roller bearing in the gearbox side. Fit in shims in the corresponding thickness. For too much play, fit in a correspondingly thicker shims. For too little play, fit in a correspondingly thinner spacer. Press in the outer ring for the conical roller bearing with DT-46757 (87 93 044 Fitting tool, to fit differential bearing race.) and KM-523-1 ( 87 93 077 Centring mandrel, handle) .
11. Remove the gearcase from DT-46750.





12. Measure the bearing play for the differential gear. Position the gearcase on the clutch housing. Tighten the gearcase with 6 bolts (M8). Fit MKM-536-A or 87 92 483 Torque wrench with DT-46758 or suitable extension and with cross-slotted socket (size 4). Test tighten the differential gear several times. Measure the friction torque with MKM-536-A - reference value: 1.2 to 1.5 Nm. If the measurement value is outside the tolerance the bearing play must be set.
Tightening torque, bolts, gearcase 25 Nm (18 ft. lbs.)
13. Remove the gearcase 6 bolts.





14. Fit the upper main shaft with gear lever shaft, 3rd/4th/reverse gear.





15. Fit the drive shaft, the lower main shaft and gear lever shaft, 1st/2nd - 5th/6th. Fit in the shafts together.
16. Fit the gearcase.
17. Fit the gearbox.