TSB : Differential Gear, Disassembling and Assembling

Details

Notes: ^ Refer to general repair instructions. ^ Make sure both tapered roller bearings on file differential gear are replaced together. If possible, use bearings from same manufacturer. 1 - Final drive cover 2 - O-ring for cover ^ Always replace 3 - Final drive housing 4 - Shim S1 ^ Note thickness 5 - Outer race of small tapered roller bearing ^ Driving out go to Fig. 10 ^ Driving in Fig. 11 6 - Inner race of small tapered roller bearing ^ Pulling off go to Fig. 2 ^ Pressing on go to Fig. 4 7 - Ring gear bolt ^ Always replace ^ Use only genuine replacement bolts ^ Counter-hold when tightening ^ Tighten in diagonal sequence ^ Tightening torque: 60 Nm (44 ft. lbs.) plus additional 1/8 turn (45°) 8 - Differential gear housing 9 - Ring gear ^ Matched with pinion (in ring gear and pinion set) ^ When replacing set, pinion and ring gear must be adjusted ^ Drive out of differential gear housing using mandrel go to Fig. 5 ^ Installing go to Fig. 6 ^ To install, warm ring gear to 100°C (212°F) 10 - Clamping sleeve ^ Drive in flush 11 - Inner race of large tapered roller bearing ^ Pulling off go to Fig. 1 ^ Pressing on go to Fig. 3 12 - Outer race of large tapered roller bearing ^ Driving out go to Fig. 12 ^ Driving in go to Fig. 13 13 - Shim S2 ^ Note thickness 14 - Threaded piece 15 - Differential bevel gears, large ^ Adjusting Figs. 8 and 9 16 - Differential bevel gears, small ^ Installing go to Fig. 7 17 - Axle for differential bevel gears ^ Drive in using mandrel ^ Drive in carefully so that thrust washers do not get damaged ^ Secure with clamping sleeve 18 - Shim ^ Determine thickness again go to Figs. 8 and 9 19 - Thrust washer ^ Check for cracks and breakage Fig. 1 Pulling off inner race of large tapered roller bearing ^ Place thrust piece 40-105 on differential gear housing before installing pulling device. Fig. 2 Pulling inner race of tapered roller bearing off of housing A- Two-arm puller (standard commercial), e.g. Kukko 44/2 Fig. 3 Installing inner race of large tapered roller bearing ^ Warm bearing to approximately 100°C (212°F) , install and press down. Fig. 4 Installing inner race of small tapered roller bearing ^ Warm bearing to approximately 100°C (212°F) , install and press down. Fig. 5 Driving ring gear off of housing Fig. 6 Installing ring gear ^ Warm ring gear to approximately 100°C (212°F) and install. A - Centering pins (hand-made); use as guide Fig. 7 Installing differential bevel gears ^ Install large differential bevel gears together with proper shim go to Figs. 8 and go to 9. ^ Install small differential bevel gears (turned 180�) and swing in (hold thrust washer in place with some grease). ^ Align thrust washers. ^ Install threaded pieces. ^ Drive axle in and secure. Fig. 8 Adjusting differential bevel gears ^ Install large differential bevel gears together with thinnest shims ( 0.5 mm ). ^ Install small differential bevel gears together with thrust washers and press in axle. From this point on, the differential bevel gears must be kept together with their respective thrust washers. ^ Press small differential bevel gears outward and check play of large differential bevel gears by hand (arrows). ^ Adjust play by installing an appropriate shim so that maximum play of 0.01 mm occurs. Notes: ^ The adjustment is also correct if no play is perceptible but it is still possible to turn the differential bevel gears - Fig. 9. ^ For available shims go to parts catalog microfiche. Fig. 9 Turning differential bevel gears Fig. 10 Driving outer race of small tapered roller bearing out of final drive housing Note: The shim(s) are damaged when removed. Fig. 11 Driving outer race of small tapered roller bearing into final drive housing ^ Install outer race uniformly using VW 295, using light hammer taps. ^ Drive in to stop as shown in illustration. Fig. 12 Driving outer race of large tapered roller bearing out of cover Note: - The shim(s) are damaged when removed. Fig. 13 Pressing outer race of large tapered roller bearing into cover