Vehicles before change point in 1982
REPLACING DRIVE PINION AND RING GEAR
- Final Drive Removed -
Drain oil.
Mount final drive on Special Tool 33 1 060.
Number of pinion/ring gear teeth is stamped in
case, e.g.
11 : 40.
Installation: Add oil¹).


¹) See Specifications

Old Version:
Unscrew bolts.
Detach drive flanges with Special Tool 33 1 250.
Installation: Tightening torque¹).


¹) See Specifications

Take off cover.
Remove differential case assembly.
Installation: On old version insert spacers in
differential case prior to installing.
Check O-ring, replacing if necessary.
Tightening torque¹).


¹) See Specifications

Remove lockplate.
Installation: Lock collar nut with new lockplate
in groove of input flange.

Hold input flange with Special Tool 33 1 000
and unscrew collar nut.
Installation: Tightening torque¹).
Press out drive pinion.
Take off shaft seal.
Remove taper roller bearing.


¹) See Specifications

Pull out bearing outer races for drive
pinion with Special Tool 33 1 350.
1 Bearing outer race, front
2 Spreader
3 Stopwasher
4 Extractor
5 Pressure bolt

1 Bearing outer race, rear
2 Streader
3 Stopwasher
4 Extractor
5 Pressure bolt

Pull in bearing outer races with Special Tool
33 1 350. Picture shows installation of rear
bearing outer race.
1 Bearing outer race
2 Rear pull-in plate
3 Nut
4 Front pull-in plate
5 Pressure bolt

Special machines pair pinions and ring gears for
optimal smooth running.
The paired number (P) is electrically engraved
on pinion and ring gear.
Never install a drive pinion and ring gear in one
car, when they have different pair numbers (P).

The figure(s) preceded by + or - indicate(s) the
amount of deviation from basic adjustment C
in hundreths of millimeters and is required to
determine thickness of shims x.
e + is added to E.
e - is subtracted from E.

Pinions and ring gears with Klingelnberg
(palloid) or Gleason teeth are installed.
Tooth back and tooth height of Klingelnberg
teeth remain constant.
In addition, the letter K will be stamped on
the ring gear and drive pinion.

The tooth back of Gleason tooth will be
higher and wider outside than inside.
In addition, the letter H or F will be stamped
on ring gear and drive pinion.

Pull off taper roller bearing with Special Tool
33 1 300.
Take off shim.
Note: Shim will be used again to facilitate
finding basic adjustment setting faster.

Press on new taper roller bearing (1) and
removed shim (A).
Coat bearing inner race with tallow to
facilitate installation.
Important: Install shim A that bevelled
inside diameter faces drive pinion.

Install drive pinion without holding sleeve.
Press front taper roller bearing on to drive
pinion with Special Tool 23 1 300 and
23 2 150.

Install drive flange without shaft seal.

Adjust frictional torque of drive pinion bearing
to 210 ... 230 Ncm (18 ... 20 in.lbs.) by
tightening collar nut.
Check frictional torque with Special Tool
00 2 000.

Determine distance C of gauge.
Place gauge on face of drive pinion.

Set micrometer dial gauge to 0 (zero) with
4 mm (0.160´´) preload.
Important: Micrometer dial gauge could
also be set with a different preload.
Determine D.
D is half of the diameter stamped on the
gauge.
For example, 40.0 mm (1.574´´) : 2 =
20.0 mm (0.787´´).

Install Special Tool 33 1 400 in case.
Read B from micrometer dial gauge and
determine Y.
Determine thickness of shim X, taking
deviation e from basic adjustment E into
consideration
E Klingelnberg........ 59.00 mm (2.323´´)
E Gleason ............. 61,85 mm (2.435´´)

Example I
1. E ........................59.00 mm (2.323´´)
e+ ............................0.15 mm (0.006´´)
______________________________
E target ..................59.15 mm (2.329´´)
2. C.........................38.00 mm (1.496´´)
D : 2........................20.00 mm (0.787´´)
______________________________
................................58.00 mm (2.283´´)
3. Gauge preload ......4.00 mm (0.158´´)
Actual value B - ........3.12 mm (0.123´´)
_______________________________
Distance Y.................0.88 mm (0.035´´)
4. C + D...................58.00 mm (2.283´´)
Y +.............................0.88 mm (0.035´´)
_______________________________
E actual...................58.88 mm (2.318´´)
5. E target................59.15 mm (2.329´´)
E actual...................58.88 mm (2.318´´)
_______________________________
a................................0.27 mm (0.011´´)
6. Test shim A............4.05 mm (0.159´´)
a - .............................0.27 mm (0.011´´)
_______________________________
Shim X.......................3.78 mm (0.148´´)
If E target is larger than E actual, a must be
subracted (-) from test shim A.
Example II
1. E.........................61.85 mm (2.435´´)
e - ............................0.12 mm (0.005´´)
______________________________
E target ................. 61.73 mm (2.430´´)
2. C........................ 38.00 mm (1.496´´)
D : 2 + ................... 20.00 mm (0.787´´)
______________________________
............................... 58.00 mm (2.283´´)
3. Gauge preload.......7.00 mm (0.275´´)
Actual value B - ........3.12 mm (0.123´´)
______________________________
Distance Y.................3.88 mm (0.152´´)
4. C + D....................58.00 mm (2.283´´)
Y +..............................3.88 mm (0.152´´)
_______________________________
E actual ....................61.88 mm (2.435´´)
5. E target..................61.73 mm (2.430´´)
E actual.....................61.88 mm (2.435´´)
_______________________________
a..................................0.15 mm (0.005´´)
6. Test shim A..............4.05 mm (0.159´´)
a + ..............................0.15 mm (0.005´´]
_______________________________
Shim X ........................4.20 mm (0.164´´)
If E target is smaller than E actual, a must be
added (+) to test shim A.
Permissible tolerance for thickness of shim X:
Klingelnberg ± 0.03 mm (0.0012´´)
Gleason + 0.04 mm (0.0016´´)

Remove drive pinion.
Pull off taper roller bearing with Special Tool
33 1 300.

Install drive pinion with shim X of determined
thickness and a new holding sleeve (1).
Important: Bevelled inside diameter of shim
X faces drive pinion.

Lubricate sealing lip of shaft seal with final
drive gear lube and knock in flush with Special
Tools 31 2 040 and 00 5 500.

Install drive flange.
Important: Collar nut must be tightened to
at least 150 Nm (108 ft.lbs.).
Adjust frictional torque of pinion bearing to
210 ... 230 Ncm (18 ... 20 in.lbs) plus 20 Ncm
(2 in.lbs.) for new shaft seal.
Check firctional torque with Special Tool
00 2 000.
Lock collar nut with a new lockplate.
If frictional torque is exceeded, replace
holding sleeve and repeat measurement.

Take off ring gear (cold).
Installation: Clean threads thoroughly (tap).
Heat ring gear to max. 100°C (212°F), checking
temperature with a thermocolor pencil.
Install new bolts with Loctite No. 270 and tighten
in order of 1 through 10.
Tightening torque¹).


¹) See Specifications

Pull off taper roller bearing with Special Tools
33 1 300 and 33 1 303.
Installation: Press on taper roller bearing cold.

Pull out bearing outer race from case with
Special Tool 33 1 350.
Important: Mark shim.

Pull out bearing outer race from cover with
Special Tool 33 1 350.
Important: Mark shim (1) and be careful
not to mix it up with shim from case.

Install old shims, if new pinion/ring gear have
same type of teeth.
This will help in finding frictional torque,
backlash and tooth pattern faster.
If pinion/ring gear with different teeth are
used, install shims 1.40 to 1.70 mm (0.055 to
0.067´´) thick for Gleason or 2.20 to 2.40 mm
(0.087 to 0.094´´) thick for Klingelnberg for
basic adjustment.

Install bearing outer race (1) and one shim
(2) in cover with Special Tool 33 1 350.

Install differential with ring gear.
Tighten cover mounting bolts¹) uniformly.


¹) See Specifications

Check total frictional torque with Special
Tool 00 2 000.
Total frictional torque must be 50 to 100 Ncm
(4 to 9 in.lbs.) more than frictional torque of
pinion bearing.
Total Frictional Torque Value Higher:
Install thinner shim.
Total Frictional Torque Value Lower:
Install thicker shim.

Install shim of determined thickness.
Install cover and recheck frictional torque.
Remove vent housing (1).
Installation: Torque values¹).


¹) See Specifications

Mount Special Tool 00 2 500 and check
backlash¹) with a dial gauge.


¹) See Specifications

Coat ring gear with printer´s ink to check
tooth contact pattern, turning ring gear in
both directions several times and stopping
with a piece of hard wood.

Backlash and tooth contact pattern can be
altered with shims 1 and 2.
Keep changing shims 1 and 2 until backlash
and tooth contact pattern are correct.
A change in shim thickness of 0.10 mm
(0.004´´) will change backlash by approx.
0.05 mm (0.002´´).
Important: Never change total thickness of
shims 1 and 2.

GENERAL INFORMATION ON TOOTH
CONTACT PATTERNS
Gleason Teeth
A
Correct tooth contact pattern without load.
A 1
Loads will shift tooth contact pattern outward
slightly.
Moving the ring gear will mainly change the
backlash, but will also displace the contact
pattern in longitudinal direction of the teeth.
Moving the drive pinion will displace the
contact pattern in favor of tooth height,
but the backlash will be altered just very
slightly.
Here are the four basic incorrect contact
patterns, which usually appear in comination.
Knowing these patterns will facilitate
making adjustments.
1. High, narrow contact pattern (tip
contact) on ring gear. Move drive
pinion toward ring gear shaft and
perhaps correct backlash by backing
ring gear off of drive pinion.
2. Deep, narrow contact pattern (root
contact) on ring gear. Move drive
pinion away from ring gear shaft and
perhaps correct backlash by moving
in ring gear.
3. Short contact pattern on small tooth
end (toe contact) of ring gear. Move
ring gear away from drive pinion.
Maybe move pinion closer to ring
gear shaft.
4. Short contact pattern on large tooth end
(heel contact) of ring gear. Move ring
gear toward drive pinion. Perhaps back
drive pinion away from ring gear shaft.

Klingelnberg (Palloid) Teeth
Tooth contact pattern on forward and reverse
flanks of drive pinion should be at approximately
center of tooth length and tooth height.
B Tooth contact pattern off load.
C Tooth contact pattern under load.
D By installing a thicker shim "X" behind
drive pinion the contact pattern of forward
flank will shift toward the large drive
pinion diameter, while on the reverse flank
it will move closer to the small drive pinion
diameter.
For other possible changes refer to drawing E.

Adjustment of contact pattern

Vehicles after change point in 1982
REPLACING DRIVE PINION
WITH RING GEAR
- Final Drive Removed -
See 33 10 010 in microfilmed repair manual
for cars beginning with 1985 models for
information on removing and installing
final drive.
Mount final drive on Special Tool 33 1 010.
Drain oil.
Unscrew case cover.
Installation:
Replace gasket.
Tightening torque*.
Pour in oil - oil volume*.
See Group 33 in Operating Material Binder
for approved oil grade.


33 10 010
* See Specifications

Pry off both drive flanges with a tire iron.

Installation:
Place round wire snap ring (1) in groove of
differential case prior to installation of the
drive flange in such a manner, that both ends
of snap ring are recessed in groove.
This prevents lateral bending of the ring.
Press in drive flange by hand and turn slightly
until snap ring is heard to engage.
Replace stretched snap rings.

Punch mark both bearing caps.
Remove both bearing caps.
Important!
Don´t mix up bearing caps and shims.
Fasten shims on bearing caps with pieces of
wire if necessary.
Installation:
Tightening torque*.


* See Specifications

Differential case bearings and backlash are
adjusted with shims (1).
Check O-ring (2), replacing if necessary.

Remove complete differential case.
Important!
Don´t bend the pulse spider.

Lift out lockplate.
Hold with Special Tool 23 0 020 and unscrew
nut (1).

Pull off input flange with Special Tool 33 1 150.
The specified friction torque* is given for new
drive pinion bearings and the frictiion torque of
old bearings does not have to be measured.


* See Specifications

Press out drive pinion.

Pull out front bearing outer race with Special
Tool 33 1 350.
1 Spreader
2 Front bearing outer race
3 Puller bell housing
4 Pressure bolt

Pull out rear bearing outer race with Special
Tool 33 1 360.
Puller consists of:
Puller head............... 33 1 361
Threaded spindle......33 1 362
Bearing bridge.......... 33 1 356
Pressure nut............. 33 1 363
Important!
Shim (X) is located underneath the rear
bearing outer race.
It will be needed again for pinion/ring gear
adjustments.

Important!
Replace both drive pinion bearings, using only
one make.

Install old shim (X) in front of the rear bearing
outer race.
Pull in bearing outer races with Special Tool
33 1 360.
Puller consists of:
Puller disc for front outer race.... 33 1 373
Puller disc for rear outer race..... 33 1 365
Threaded spindle....................... 33 1 362
Pressure nut............................... 33 1 363
Nut............................................. 33 1 354

Press new tapered roller bearing inner race on
to new drive pinion with Special Tool 33 1 020.

Important!
Drive pinions and ring gears are paired for
optimal smooth running in special machines.
The pairing code (P) is inscribed electrically
on the drive pinion and ring gear.
Never install a ring gear and drive pinion
with different pairing codes (P) together.
H = Gleason hypoid teeth (helical shape).

The number inscribed together with "+" or
"-" is the deviation from basic distance C
in hundreds of millimeter and is required
for adjustment of the tooth contact pattern
with shims.
+ e is added to C.
- e is subtracted from C.

To determine the thickness of shim (X), install
drive pinion with new tapered roller bearings,
but without bush.

Install drive pinion in rear bearing outer race.
Press (don´t pull) front tapered roller bearing
on to drive pinion with Special Tool 23 1 300
in conjunciton with a spacing sleeve.

Mount input flange.
Tighten collar nut in steps and measure friction
torque after each step with Special Tool
00 2 000, adjusting it to 250 Ncm (22 in.lbs.)
with the collar nut.

- Drive Pinion Block Distance -
Mount dial gage in Special Tool 33 1 481.
Place Special Tool 33 1 481 with dial gage on
Special Tool 33 1 482 and set dial gage to 0
(zero) with pre-load.

Place Special Tool 33 1 482 on drive pinion.
Insert Special Tool 33 1 481 in case.
Determine value Y.
Basic distance C = 11.50 mm (0.453´´)
Gage disc B = 9.50 mm (0.374´´)

Example I
C ..........................................11.50 mm (0.453´´)
e +..........................................0.10 mm (0.004´´)
_____________________________________
C nominal .............................11.60 mm (0.457´´)
Y measured on dial gage........1.90 mm (0.075´´)
+ gage thickness B.................9.50 mm (0.374´´)
_____________________________________
C actual ...............................11.40 mm (0.449´´)
C nominal .............................11.60 mm (0.457´´)
C actual..............................- 11.40 mm (0.449´´)
_____________________________________
a.............................................0.20 mm (0.008´´)
Test shim A.............................4.10 mm (0.161´´)
- a...........................................0.20 mm (0.008´´)
_____________________________________
Shim thickness X....................3.90 mm (0.153´´)
If C nominal is larger than C actual, "a" is
subtracted (-) from shim thickness X.
Example II
C .............................................11.50 mm (0.453´´)
e - .............................................0.10 mm (0.004´´)
_______________________________________
C nominal ................................11.40 mm (0.449´´)
Y measured on dial gage...........2.20 mm (0.087´´)
+ gage thickness B....................9.50 mm (0.374´´)
_______________________________________
C actual ...................................11.70 mm (0.461´´)
C actual ...................................11.70 mm (0.461´´)
C nominal ...............................- 11.50 mm (0.453´´)
_______________________________________
a ................................................0.20 mm (0.008´´)
Test shim A ................................3.90 mm (0.153´´)
+ a .............................................0.20 mm (0.008´´)
_______________________________________
Shim thickness X........................4.10 mm (0.161´´)
If C nominal is smaller than C actual, "a" is
added (+) to shim thickness X.
The permissible tolerances for distance (X) result from the tolerances for shim thickness in steps
of 0.01 to 0.03 mm (0.0004 to 0.0012´´).

Remove drive pinion and rear bearing outer
race.
Press in shim (X) of dertermined thickness and
bearing outer race.

Important!
Do not install the drive pinion at this point,
since it is first necessary to measure and
adjust the friction torque of the new
differential case bearing.

Press pulse spider off of differential case.
Caution!
Be careful not to bend the pulse spider.

Installation:
Press on pulse spider with Special Tool
33 1 304.

Remove ring gear (cold).
Installation:
Clean threads thoroughly (with a tapper).
Heat ring gear to max. 100°C (212°F),
checking temperature with a thermochrome
pencil.
Mount ring gear with two locally made staybolts
as guides.

Install new bolts with Loctite No. 270 and
tighten in order of (1 ... 10).
Tightening torque*.
Tighten bolts to torque angle*.


* See Specifications

Pull off tapered roller bearing on differential
case with Special Tool 33 1 300.

Installation:
Press on new tapered roller bearing inner races
cold with Special Tool 33 1 003.

Lift shaft seals out of both bearing caps.

Press out bearing outer race with Special Tools
33 1 350 and 33 1 351.
Important!
Special Tool 33 1 351 must engage in the
bearing outer race.

Installation:
Press in new bearing outer races with Special
Tool 33 1 365.

The following 12 steps can only be omitted,
if the differential case bearings were not
replaced.
Install differential case with new ring gear and
new bearings.
Lubricate bearings thoroughly with approved
final drive gear lube** and let them drip dry.


** See Gr. 33 in Operating Material Binder

Install side bearing caps marked with belonging
shims (1), but at first without O-rings (2).
Tighten bearing cover bolts on the side opposite
the ring gear uniformly.
Tightening torque*.


* See Specifications

The compensation bore (1), which is recongnized
on the outside by tab (2), always faces up in
installed position of the transmission.

Determining Friction Torque of New Differential
Case Bearings:
Axial preload force (4000 N = 882 lbs.) of
differential case bearings can be determined
with help of the friction torque*.
Tighten bolts of second bearing cap uniformly
only enough, that the differential can
still be turned easily.


* See Specifications

Install an output flange on the end opposite
the ring gear and determine the friction
torque with a locally manufactured holder
with welded nut and Special Tool 00 2 000.
Turn friction tester at approx. 50 rpm.

The friction torque* specified in the differential
case bearing table* should be reached,
but not exceeded.
If new shaft seals had already been installed,
add 20 Ncm (2 in.lbs.) for each seal in which
an output shaft runs while measuring.


* See Specifications

If the given friction torque is not reached,
even though both bearing caps are tightened
to the correct tightening torque*, install a
thinner shim opposite the ring gear and
repeat the measuring procedures.


* See Specifications

If the friction torque is reached, even though
the second bearing cap has not yet been
tightened to the correct tightening torque*,
a thicker shim must be used on the ring gear
end and the measuring procedures repeated.


* See Specifications

To make finding the shim thickness easier, the
distance between the shim and case can be
measured with a feeler gage blade and added
to the thickness of the used shim.

Example:
Second bearing cap not tightened fully
(bolts screwed in uniformly).
Specified friction torque* (e.g. 190 Ncm =
16.5 in.lbs.) is reached and shaft seals are
not yet installed.
Gap measured with blade
of feeler gage.................... 0.20 mm (0.008´´)
Used shim thickness......... 1.40 mm (0.055´´)
____________________________________
Install shim of thickness..... 1.60 mm (0.063´´)
and measure again.

Remove differential for installation of the
drive pinion.
(If differential case bearings were not replaced,
procedures can be continued from this
point).
Important!
Arrange side covers and shims of determined
thickness; don´t mix them up.

Install drive pinion with a new clamping
sleeve (2).

Dip shaft seal in final drive gear lube and
drive it in flush with Special Tools 33 1 270
and 00 5 500.

Press (don´t pull) input flange on to the
input shaft with Special Tools 23 1 300.
Axial preload force (5000 N = 1102 in.lbs.)
of drive pinion bearings can be determined
with help of the friction torque.

Tighten input flange with the collar nut in steps,
measuring the frictiion torque after each step
(see below).

Measure friction torque* with Special Tool
00 2 000 and a suitable wrench socket.
Important!
The relation between friction torque and
preload force differs depending on the make
of bearings.
Take specified friction torque from the pinion
bearing table* and add 20 Ncm (2 in.lbs.) for
the new shaft seal.


* See Specifications

Insall differential.
Install side covers as marked with corresponding
washers (1) and new O-rings (2).
Tighten bolts uniformly.
Tightening torque*.


* See Specifications

- Backlash/Tooth Contact Pattern Adjustment -
Mount Special Tool 00 2 500 and measure
backlash* with dial gage.
Important!
The tooth contact pattern is always most
important for a perfectly adjusted pinion/ring
gear set.


* See Specifications

To check the tooth contact pattern, coat the
ring gear teeth with printer´s ink, turn in both
directions several times and stop ring gear
suddenly with a piece of hard wood.

Correct backlash* and tooth contact pattern
by changing the thickness of both shims (1).
If backlash is excessive, use a thinner shim on
the ring gear end.
If backlash is too small, use a thicker shim on
the ring gear end.
An axial displacement of the ring gear by 0.01 mm
(0.0004´´) will cause a change in backlash
of 0.0076 mm (0.0003´´).
Important!
The total thickness of both shims must not be
changed.
If a thinner or thicker shims is required to
correct the tooth contact pattern, the total thickness
must be corrected with the second shim,
since otherwise the friction torque of bearings
would be changed again.


* See Specifications

Refer to following pages for general information
on tooth contact pattern adjustments.

Installation:
Dip new shaft seals in final drive gear lube.
Drive in shaft seals against the stop with
Special Tools 33 1 230 and 00 5 500.
Replace a drive flange with seriously scored
bearing surfaces.

Drive in new lockplate with Special Tools
33 4 050 and 00 5 500.

GENERAL INFORMATION ON TOOTH PATTERN ADJUSTMENTS
Gleason Teeth
A Correct tooth pattern without load.
A1 Loads will shift tooth contact pattern outward slightly.
Moving the ring gear will mainly change the backlash, but will also displace
the contact pattern in longitudinal direction of the teeth.
Moving the drive pinion will displace the contact pattern in favor of tooth
height, but the backlash will be altered just very slightly.
Here are the four basically incorrect contact patterns, which usually occur
in combination.
Knowing these pattern will facilitate making adjustments.
1. High, narrow contact pattern (tip contact) on ring gear. Move drive
pinion toward ring gear shaft and perhaps correct backlash by backing
ring gear off of drive pinion.
2. Deep, narrow contact pattern (root contact) on ring gear. Move drive
pinion away from ring gear shaft and perhaps correct backlash by moving
in ring gear.
3. Short contact pattern on small tooth end (toe contact) of ring gear.
Move ring gear away from drive pinion. Maybe move pinion closer to
ring gear shaft.
4. Short contact pattern on large tooth end (heel contact) of ring gear.
Move ring gear toward drive pinion. Perhaps back drive pinion away
from ring gear shaft.

Adjustment of contact pattern