You will need: 15 mm socket head, universal puller, bearing press mandrel, flat-blade screwdrivers, punch, hammer.
1. If the speedometer drive gear teeth are heavily worn, replace the gear. To do this, spread the ends of the locking ring with a screwdriver and at the same time use a second screwdriver to slide the gear along the differential box journal together with the ring.
2. To replace a worn or damaged bearing, press it off the differential case journal.
Attention!
- A bearing pressed in the manner shown is not suitable for reinstallation, as its separator is damaged. Therefore, do not dismantle the differential bearings unless necessary.
- When replacing differential bearings, be sure to replace their outer rings installed in the adjusting nut and bearing cap (see Disassembly and assembly of the gearbox, inspection of its parts).
3. Remove the ten bolts securing the driven gear of the final drive to the differential box.
4. Mark the relative positions of the gear and the box…
5. …press the gear off the differential box with light hammer blows through a wooden spacer…
6. …and remove the gear.
7. Using a 3.2 mm punch, knock out the satellite axle retaining pin…
8. …and remove the satellite axle from the differential box.
9. While turning the differential gears, remove the satellites from the differential box…
10. …and axle gears.
Please note…
...on satellites..
...and the axle gears have thrust washers installed. When reassembling, do not forget to install them in their original places.
11. Inspect the working surfaces and teeth of the satellites, splines and teeth of the axle gears. If the working surfaces, splines and teeth are heavily worn, or if the teeth are chipped, replace the differential gears.
12. Inspect the gear support washers. If the washers are visibly worn, replace them
13. Inspect the differential case surfaces in the areas where the gear support washers operate. If the surfaces are heavily worn, replace the differential case.
14. Remove small irregularities on the pinion journals with fine-grained sandpaper. If the metal of the pinion journals is dragged or if they are worn on one side, replace the axle.
15. If there are chips, pitting or significant wear on the teeth of the driven gear of the main transmission, replace the gear.
Note: When replacing the final drive driven gear, the pinion gear must also be replaced at the same time (secondary shaft), since these gears are selected based on noise and are installed only in pairs.
16. Assemble the differential in the reverse order of disassembly, taking into account the following:
- press the satellite axle locking pin into the differential box hole on the side where it was knocked out;
- press the differential bearings onto the differential box journals, applying force to the inner ring;
- before pressing the speedometer drive gear onto the differential box journal, heat the gear in an oil bath to a temperature of 80°C;
- press the driven gear of the main transmission onto the differential box, aligning the marks made during disassembly and heating the gear in an oil bath to a temperature of 100°C;
- lubricate the threaded portion of the driven gear mounting bolts with anaerobic thread locker, tighten the bolts evenly in a crisscross pattern. Finally tighten the bolts to a torque of 70 N·m (7.0 kgf·m).
(The source is on the online website: OPELBOOK)
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