Final Drive, Replacing
Final drive, replacing
Special Tools:
951 2928 Ball hex 6MM/3/8 951 2928 Ball Hex 6mm/3/8
998 5972 Jack 998 5972 Jack
999 7057 Counterhold 999 7057 Counterhold
Note! Since illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information is always correct.
Removal
Preparations
Note! Check that the parking brake is not applied and that the gear selector is in position P.
Ignition off
Position the rear lifting arms so that they do not obstruct the front brackets securing the rear axle arms to the body.
Removing drive shafts
Remove the drive shafts on both sides. See Drive shaft rear, replacing Drive Shaft Rear, Replacing.
Removing the spare wheel and rear section of the exhaust system
Remove the rear section of the exhaust system and the spare wheel.
Support the rear edge of the three-way catalytic converter (TWC) so as not to put strain on the exhaust manifold.
Pay attention to the following when removing propeller shaft
Note! Applies to 6-cylinder engines only.
Follow instructions. Refer to: Propeller shaft, special information Description and Operation
Remove the propeller shaft from the final drive. Remove the member for the center bearing. See Propeller shaft, replacing Propeller Shaft.
Removing the screws for the propeller shaft/center bearing member
Tie up the shaft.
Use the rear cross member as support.
Remove one screw and slacken off the other. Turn out the member.
Removing the cable harness
Remove the connector from the Differential Electronic Module (DEM).
Detach the cable harness from the final drive housing and the mounting in the rear axle member.
Fold the cable harness to one side to prevent damage when removing the final drive.
Removing the final drive
Remove:
- the cover for the rear axle member
- the screw for the front mounting for the final drive housing.
Slacken off the 2 rear screws for the rear axle member/final drive housing. Leave the screws in place by a few threads.
Removing the rear axle member
Bring the jack into light 998 5972 JACK 998 5972 Jack contact under the front section of the rear axle member.
Remove the screws from the front mounting in the body for the rear axle member, on both sides.
Carefully lower the frame. Remove the jack.
Removing the final drive housing
Support the final drive housing and remove the 2 loose screws.
Lift out the final drive housing from the rear axle member. Position the final drive housing on a workbench.
Replacing the final drive housing
When replacing the final drive, see Final drive, transferring components.
Installation
Note! For tightening torques, see Tightening Torque
Note! To make sure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling.
Installing the rear axle member
Install the final drive housing in the rear axle member. Loosely secure the final drive housing to the rear bushings in the frame using screws.
Bring the jack into light 998 5972 JACK 998 5972 Jack contact under the front section of the rear axle member.
Install the screws in the front mounting for the rear axle member in the body on both sides.
Install the 2 M12 screws for the bracket/body.
Tighten.
Install the screw for the bracket/rear axle member/body, 1 x M12 or 1 x M14 (2005-). Tighten. See Tightening torque, B6324S Tightening Torque.
Remove the mobile jack.
Installing the final drive housing
Install:
- 1 M12 front screw for the final drive housing. Tighten
- the cover for the rear axle member using 4 M12 screws. Tighten
- the 2 rear M12 screws for the sub-frame/final drive housing. Tighten.
Installing the cable harness
Connect the connector to the control module for the differential electronic module (DEM). Install the cable harness in the mounting in the rear axle member.
Install the propeller shaft on the final drive. Install the member for the center bearing. See Propeller shaft, replacing Propeller Shaft.
Installing drive shafts
Install the drive shafts on both sides. See Drive shaft rear, replacing Drive Shaft Rear, Replacing.
Installing the spare wheel and rear section of the exhaust system
Check that the gasket for the flanged joint between the front and rear exhaust pipe is not damaged. Replace if necessary.
Install the rear cross member. Use 2 x M8 screws. Tighten.
Filling and checking the oil level
Fill and check oil in the clutch (AOC). The front level plug is for the clutch (AOC). Only use oil with part number 116 1641 (0.3 liter container)
Fill the final drive with oil. Check the oil level. The rear level plug is for the final drive. Only oil P/N 116 1620-8 (1 liter containers) may be used
Tighten both level plugs. See Tightening Torque