Vehicles after change point in 1982
REPLACING DRIVE PINION
WITH RING GEAR
- Final Drive Removed -
Remove final drive - see 33 10 010 in repair
manual of pertinent model series beginning
with 1985 models.
Remove complete differential.
Important!
Mark bearing covers - do not mix up washers.


Siehe auch 33 10 010
73033254 - click to zoom
 
Lift out lockplate.
Unscrew nut (1), counterholding with
Special Tool 23 0 020.

2033073 - click to zoom
 
Pull off input flange with Special Tool
33 1 150.
The specified friction torque is given with the
new drive pinion bearing, so that the friction
torque of the old bearing does not have to be
measured.

73033266 - click to zoom
 
Press out drive pinion.
Caution!
Be careful not to damage threads.

73033272 - click to zoom
 
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

2833012 - click to zoom
 
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.

2833013 - click to zoom
 
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

2833014 - click to zoom
 
Press tapered roller bearing on to drive pinion
with Special Tool 33 1 330.

2833015 - click to zoom
 
Important!
Drive pinions and ring gears are matched in
special machines for optimum smooth running.
The pair code (P) is electrically inscribed in
the drive pinion and ring gear.
Never install a ring gear and drive pinion with
different pair codes together.

2833016 - click to zoom
 
The number inscribed with + or - is the
deviation from basic distance C in 1/100ths of
millimeters and is required to determine the
thickness of shims.
e+ is added to C.
e- is subtracted from C.
H indicates type of teeth.
H = Gleason.

2833017 - click to zoom
 
To determine the thickness of shim (X), install
drive pinion with new tapered roller bearings,
but without bush.

2833018 - click to zoom
 
Place drive pinion in rear bearing outer race.
Apply Special Tool 33 1 341 on drive pinion
and pull front taper roller bearing on to drive
pinion with Special Tools 23 1 300 and
33 1 342.

2033017 - click to zoom
 
Attach input flange.
Adjust friction torque of drive pinion roller
bearing to 250 Ncm (22 in.lbs.) by tightening
collar nut.

3033039 - click to zoom
 
Mount dial gage in Special Tool 33 1 411.
Place Special Tool 33 1 411 with dial gage on
Special Tool 33 1 412 and set dial gage to 0
(zero) with pre-load.

73033081 - click to zoom
 
Place Special Tool 33 1 412 on drive pinion.
Place Special Tool 33 1 411 in case.
Determine value Y.
Basic distance C = 18.50 mm (0.728´´)
Gage thickness B = 17.50 mm (0.689´´)

73033074 - click to zoom
 
Example I
C.......................... 18.50 mm (0.728´´)
e- .........................- 0.30 mm (0.011´´)
_____________________________
C target ................18.20 mm (0.717´´)
_____________________________
Value Y measured
on dial gage...........0.60 mm (0.023´´)
Sum B..................17.50 mm (0.689´´)
Sum Y.................+ 0.60 mm (0.024´´)
____________________________
C actual...............18.10 mm (0.713´´)
____________________________
C target................18.20 mm (0.717´´)
C actual.............- 18.10 mm (0.713´´)
____________________________
a............................0.10 mm (0.004´´)
____________________________
Gage A..................4.14 mm (0.163´´)
-a...........................0.10 mm (0.004´´)
____________________________
Shim X...................4.04mm (0.159´´)
If target C is larger than actual C, "a" is
subtractecd (-) from thickness of shim X.
Example II
C..........................18.50 mm (0.728´´)
e+.......................+ 0.10 mm (0.004´´)
_____________________________
C target................18.60 mm (0.732´´)
_____________________________
Value Y measured
on dial gage............1.20 mm (0.047´´)
Sum B...................17.50 mm (0.689´´)
Sum Y..................+ 1.20 mm (0.047´´)
_____________________________
C actual ................18.70 mm (0.736´´)
_____________________________
C actual.................18.70 mm (0.736´´)
C nominal.............- 18.60 mm (0.732´´)
_____________________________
a..............................0.10 mm (0.004´´)
_____________________________
Gage A....................4.10 mm (0.161´´)
+a............................0.10 mm (0.004´´)
_____________________________
Shim X.....................4.20 mm (0.165´´)
If target C is smaller than actual C, "a"
is added (+) to thickness of shim X.
The permissible tolerance for distance (X) results from the graduation
of 0.01 to 0.03 mm (0.0004 to 0.0012´´) depending on shim thickness.

73033080 - click to zoom
 
Remove drive pinion and rear bearing outer
race.
Press in shim (X) of determined thickness and
bearing outer race.

2833014 - click to zoom
 
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.

3033268 - click to zoom
 
Press pulse spider off of differential case.
Caution!
Be careful not to bend the pulse spider.

2033011 - click to zoom
 
Installation:
Press on pulse spider with Special Tool
33 1 304.

73033136 - click to zoom
 
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.

2033024 - click to zoom
 
Install new bolts with Loctite No. 270 and
tighten in order of (1 ... 10).
Tightening torque*.
Tighten bolts to torque angle*.


Siehe auch * See Specifications
2033025 - click to zoom
 
Pull off tapered roller bearing on differential
case with Special Tool 33 1 300.

2833067 - click to zoom
 
Installation:
Press on new tapered roller bearing cold with
Special Tool 33 1 003.

2833022 - click to zoom
 
Lift shaft seals out of both bearing caps.
Installation:
Dip new shaft seals in final drive gear lube.
Drive in shaft seals against stop with Special
Tools 33 1 230 and 00 5 500.

73033259 - click to zoom
 
Prress 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.

73033138 - click to zoom
 
Installation:
Press in new bearing outer races with Special
Tool 33 1 365 or 33 1 368.

73033139 - click to zoom
 
The following 12 steps can only be omitted,
if the differential case bearings were not
replaced.
Install dirfferential case with new ring gear and
new bearings.
Lubricate bearings thoroughly with approved
final drive gear lube** and let them drip dry.


Siehe auch ** See Service Information of Gr. 00
73033273 - click to zoom
 
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*.


Siehe auch * See Specifications
73033274 - click to zoom
 
- Friction Torque of Differential Case
Bearings -
Only tighten the bolts of the second bearing
cap uniformly as long as the differential can
still be turned.

73033275 - click to zoom
 
Apply an output flange on the side tightened
to the tightening torque and measure the
friction torque with a locally made clamp with
a welded nut and friction torque meter
00 2 000.
Turn friction torque meter at speed of approx.
50 rpm.

73033276 - click to zoom
 
The friction torque value given with the new
differential bearing set +20 Ncm (2 in.lbs.)
for each new shaft seal in which a shaft runs
while measuring, should be reached, but must
not be exceeded.

73033277 - click to zoom
 
If the given friction torque is not reached,
even though both bearing caps are tightened
to the correct tigthening torque*, install a
thinner shim opposite the ring gear and
repeat the measuring procedures.


Siehe auch * See Specifications
73033278 - click to zoom
 
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.


Siehe auch * See Specifications
73033279 - click to zoom
 
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.

73033280 - click to zoom
 
Example:
Second bearing cap not tightened (bolts
screwed on uniformly).
Friction torque value specified in the bearing
set package: 180 Ncm (15 in.lbs.).
1 Output flange inserted
New shaft seal: 20 Ncm (2 in.lbs.).
Measured friction torque: 200 Ncm (17 in.lbs.).
Gap measured with
feeler gage blade......................... 0.20 mm (0.008´´)
Used shim thickness:................... 1.40 mm (0.055´´)
_________________________________________
Install shim of thickness:.............. 1.60 mm (0.063´´)
and repeat measuring procedures.

3033295 - click to zoom
 
Remove differential to install the drive
pinion.
(If the differential case bearings had not been
replaced, it is allowed to continue from this
point).
Important!
Do not mix up side covers and shims.

73033263 - click to zoom
 
Install drive pinion with a new sleeve (2).
Drive in shaft seal and bolt input flange.

2033016 - click to zoom
 
Important!
Tighten collar nut (1) in steps and measure the
friction torque between steps with Special
Tool 00 2 000.
Only tighten the collar nut enough, that the
friction torque given with the new tapered
roller bearing plus 20 Ncm (2 in.lbs.) for the
new shaft seal is reached.
The friction torque should be reached, but
not exceeded.
If the friction torque is exceeded, sleeve (2)
will have to be replaced and the measuring
procedures repeated.

3033020 - click to zoom
 
Install differential.
Install side covers according to marks with
corresponding washers (1) and new O-rings (2).
Tightening torque*.


Siehe auch * See Specifications
3033225 - click to zoom
 
- 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.


Siehe auch * See Specifications
73033078 - click to zoom
 
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.

2833027 - click to zoom
 
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 shim 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.


Siehe auch * See Specifications
2833029 - click to zoom
 
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 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.

2833030 - click to zoom
 
Adjustment of contact pattern

31633044 - click to zoom