Cover Differential, Replacing

Cover differential, replacing

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work

Draining the cooling system
Drain the cooling system. See: Radiator, replacing Radiator, Replacing.

Removing the bevel gear/chain housing

Remove:
- the bevel gear/chain housing (LHD). See: Replacing the pinion seal for the bevel gear. Seals Bevel Gear/Chain Housing, Replacing
- the bevel gear/chain housing (RHD). See: Bevel gear/chain housing, replacing. Seals Bevel Gear/Chain Housing, Replacing

Removal

Disconnecting the pipe from the turbocharger (TC)




Remove the lower of the 2 pipe screws for the turbocharger (TC) water cooling.
Slacken off the cap nut for the cooling pipe for the oil cooler. Remove the 2 screws for the flange on the oil return line for the turbocharger (TC). Remove the pipe and the sealing ring. Install a rubber plug as a seal in the cylinder block.

Removing the bracket for the bevel gear/chain housing




Remove the bracket from the transmission and the engine.

Removing the transmission output speed sensor from the cover on the transmission





Place a container underneath the transmission.

Remove:
- the screw that holds the sensor and the tie strap for the cable for the sensor
- the sensor
- the screws for the cover
- the cover.

Note! Remove the throw-out bearing from the differential or the cover if it is still in place.

Checking the bearing surface on the differential




Check the bearing surface on the differential. There must not be any visible scratches or abnormal wear on the bearing surface.

Installing the spacer washer and throw-out bearing




Install the spacer washer and the throw-out bearing on the differential. Apply a little petroleum jelly on the throw-out bearing so that it secures against the spacer washer.

Install:
- the spacer washer against the pulse wheel
- the throw-out bearing, see the illustration.

Installing the differential housing cover




Reinstall the cover on the transmission.
Check that all mating surfaces are clean. Use a new sealing ring. Install the cover using 3 M10 screws. Tighten alternately to light contact. Tighten.

Note! There must be axial clearance of 0.12 mm - 0.67 mm between the differential and the differential housing cover.

Installing the transmission output speed sensor




Check that the O-ring for the sensor is intact. Tighten the M6 screw. Clamp the cable for the sensor to the transmission housing using a tie strap.

Installing the bracket for the bevel gear/chain housing




Install the bracket on the cylinder block using 2 M10 screws and the M8 screw. Tighten the screw so that the bracket can just be moved.
Install the M10 screw for the bracket and transmission. Tighten. Tighten the screws for the bracket. Install the screw for the heat deflector plate

Installing the pipe on the turbocharger (TC)




Install a new O-ring on the oil return line and press it into the cylinder block. Install a new gasket for the pipe flange and the 2 M6 screws. Tighten.
Tighten the cap nut for the cooling pipe for the oil cooler.
Install the pipe screw and seal washers for the turbocharger (TC) water cooling. Tighten. See Tightening torque, B6324S Tightening Torque.

Finishing

Installing the bevel gear / chain housing

Install:
- the bevel gear/chain housing (LHD). See: Replacing the pinion seal for the bevel gear. Seals Bevel Gear/Chain Housing, Replacing
- the bevel gear/chain housing (RHD). See: Bevel gear/chain housing, replacing. Seals Bevel Gear/Chain Housing, Replacing

Filling the cooling system
Fill the cooling system. See: Radiator, replacing Radiator, Replacing.