Differential-Earlier Version

TO REMOVE AND DISMANTLE
To replace parts inside the differential, remove one of the circlips securing the differential pinion shaft. The shaft, pinions and wear washers can be removed without the need for removing the crown wheel.

1. Remove the differential housing cover.
2. Remove the two differential bearing housings together with the inner universal joint driver. Save any shims and remove the differential.





3. If necessary, press the outer races of the bearings out of the bearing housings. (See description of removal of the inner universal joint driver with differential bearing housings.)
Remove the speedometer drive and use tools 89 96 084, 87 90 768 and 89 95 177 to press the two bearings out of the differential housing.
4. Remove the crown wheel bolts and remove the crown wheel.
5. Press out the differential pinion shaft. The hole marked with a white spot is somewhat smaller, and the shaft must be pressed out from this side.
6. Remove the pinions and wear washers from the differential.

TO ASSEMBLE AND FIT

IMPORTANT NOTE: The crown wheel and pinion must always be replaced together, since they are a matched pair.

1. Replace any worn or damaged parts by new ones.





2. Fit the differential pinions with their wear washers into their seats in the differential and press in the differential pinion shaft. Press the shaft in from the side which is not marked with a white spot.





3. Fit the crown wheel and tighten the bolts to a torque of 50 Nm (37 lb ft). Lock the crown wheel bolts with locking compound.
Tightening torque: 50 Nm (37 lb ft).
As from the 1982 model with a final drive ratio of 9:33 and M10 x 1.25 mm bolts, tighten to a torque of 90 +/- 10 Nm (66 +/- 7 lb ft).





4. Press the bearings into place and fit the speedometer drive. Use tool 87 90 487.
5. Fit the differential into the gearcase. If any part affecting the overall width of the differential has been replaced, such as the bearings, adjust the crown wheel backlash. This is done by adjusting the shimming as described under "To adjust the crown wheel backlash".
6. For particulars of fitting the outer races into the bearing seats, see under "Inner universal joint driver with bearing housings, To assemble".





Fit the differential bearing housings with inner drivers. Apply sealing compound to the threads of the 12 bolts.
Tightening torque for the differential bearing housings: 23-28 Nm (17-21 lb ft)

7. Fit the differential housing cover.