184001130 - 2110D20 DIFFERENTIAL INNER CASE, REMOVED - DISMANTLE AND REBUILD, CHECK PLANET AND DIFFERENTIAL GEARS

Removing ( Refitting ) Position the complete differential in a vice with protective jaws.1. Remove the bearing (1a) with a suitable puller (1b) with jaws (1c) and a reaction base (1d).

NameCountry
1bExtractor1.840.005.001

NameCountry
1bExtractor Arms1.840.005.302

NameCountry
1bPad1.845.028.000
1. Remove the bearing (1a) with the tools (1b), (1c), (1d) and (1e).

NameCountry
1bExtractor1.840.005.001

NameCountry
1bExtractor Arms1.840.005.302

NameCountry
1bPad1.845.028.000

NameCountry
1bExtractor1.842.133.000
2. Remove the speedometer drivegear.3. Remove the planet gears.
1. Using a suitable chisel (1a), break open the wall of the differential casing at point (1b) to that the flexible pin which retains the differential satellite gear carrier can be removed.
1. Remove the differential satellite gear carrier flexible retaining pin (1a) using a suitable punch (1b).2. Remove the differential satellite gear carrier.3. Remove the satellite gears.
1. Remove the satellite and planet gear metal thrust washers.
Refitting ( Removing ) Check that the satellite and planet gears are intact and that there are no signs of seizing.Fit the satellite and planet gear metal thrust washers.Fit the differential satellite carrier and the satellite gears.1. Fit the flexible pin securing the differential satellite carrier using a suitable punch.After fitting the flexible pin, stake the differential casing to prevent it coming out.
1. Place the planet gears on the satellite gears and, by rotating them on the satellites, fit them in their seatings in the casing.2. Fit the speedometer drivegear.3. Fit the bearing (3a) with the tools (3b) and (3c).

NameCountry
3bFitting tool1.870.469.000

NameCountry
3cGrip1.870.007.000
1. Fit the bearing (1a) with the tool (1b).

NameCountry
1bFitting tool1.870.632.000
Removing ( Refitting ) 1. Remove the bearings (1a) from the differential internal housing using the tools (1b), (1c) and (1d).

NameCountry
1bExtractor1.840.005.003

NameCountry
1cExtractor Arms1.840.005.302

NameCountry
1dFitting tool1.875.017.000
1. Remove the speedometer idler gear (1a) using the tools (1b), (1c) and (1d).

NameCountry
1bExtractor1.840.005.003

NameCountry
1cExtractor Arms1.840.005.302

NameCountry
1dFitting tool1.875.017.000
Mark the relative position of the ring gear and the differential internal housing.1. Undo the bolts (1a) and remove the ring gear (1b).
1. Remove the satellite carrier bearing using a suitable drift.
The circlip will be cut during this operation.
2. Extract the satellite gears (2a) and the washers (2b).3. Remove the planet gears.
Refitting ( Removing ) Check that the satellite and planet gears are intact and that there are no signs of seizing.Fit the planet gears.Fit the satellite gears and washers.Fit the satellite carrier bearing using a suitable drift.Fit a new satellite carrier bearing retaining pin using a suitable drift.Using a screwdriver, check that the matching between the planet and satellite gears is correct making sure that they rotate without clearance and with slight resistance.Fit the ring gear checking the marks made during the dismantling and fix it tightening the bolts to torque.

FasteningComponentØValue(daNm)
-BoltDIFF CROWN WHEELM107.7 - 9.2
Fit the speedometer idler drive gear after having heated it to a temperature of 100° ¸ 120°C.1. Fit the bearings (1a) in the differential internal housing using the tool (1b).

NameCountry
1bFitting tool1.875.017.000
Removing ( Refitting ) Position the complete differential in a press.1. Position the tool (1a) on the differential casing bearing and using tool (1b) remove the bearing (1c) and adjustment shim (1d) from the seating on the differential casing.

NameCountry
1aExtractor1.870.845.000

NameCountry
1bGrip1.870.007.000
Remove the differential tapered bearing, crownwheel side, using the same procedure and tools shown above.
Mark the compensation washer and its housing, because the correct position is vital for calculating the new washer or refitting it correctly.
1. Undo the bolts securing the differential crownwheel.2. The cylindrical crownwheel is an interference fit on the casing, so use a rubber hammer to extract the cylindrical crownwheel.
1. Remove the retaining clip (1a) and withdraw the differential gearbox satellite gear carrier pin.2. Remove the satellite gears.3. Remove the differential gears (3a) and thrust washers (3b).
Refitting ( Removing ) Check the condition of the satellite and planet gears.Fit the differential gears and their thrust washers.Fit the planet gearsFit the planet carrier pin and lock it on the differential casing with its retaining clip.Fit the crownwheel on the differential casing and tighten the bolts for centring the holes on the casing.Using a rubber hammer, insert the crownwheel in its seating in the differential casing.Undo the fixing bolts and replace them with new ones.Apply thread locking compound and tighten them to the specified torque.

FasteningComponentØValue(daNm)
-BoltDIFF CROWN WHEEL-8 - 9
1. Bring the differential case to a press, and using the drift (1a), install the tapered bearing (1b) in the differential case complete with old adjustment shim.

NameCountry
-Grip1.870.007.000
Fit the differential tapered bearing, crownwheel side, using the same procedure and tools shown above.
If excessive wear of the differential casing is observed before dismantling and its replacement is necessary, carry out the following measurements.The measurements given below are necessary in order to calculate the increase or reduction to be applied to the adjustment shims in order to maintain the correct alignment between the differential crownwheel and the lay shaft gear.Remove the differential casing bearings. 2110D26 differential inner case bearings - replace with differential inner case removed 1. The procedure for calculating thickness S1 is described below.
1. Bring the differential casing (1a) to the measurement surface and measure the height 'A' (1b) between the bearing seat and the ring gear seat.Distance 'A' will be designated as 'Av' for the old differential casing and as 'An' for the new differential casing.Take more than one measurement and calculate the average value. Carry out the same operation on the new differential casing as well without tapered bearings.Subtract the average height value of the new differential casing 'An' from the average height value of the old differential casing 'Av'.Add the value taken (absolute value) to the old shim S1v ('v' indicating the old casing) determined previously thereby defining the value of the new compensation washer S1n ('n' indicating the new shim for the new casing).S1n = S1v + (Av - An)
1. The procedure for calculating shim S2n (New) is described below.
Measure the thickness of shim S2v (Old) and make a note of it.Measure the height 'B' of the differential casing between the bearing seats.1. Bring the differential casing (1a) to the measurement surface and measure the height (1b) between the bearing seats.2. Measure the heights (2a) and (2b) of the two bearings.
Take more than one measurement and calculate the average.
Take these measurements for both the new and old differential casings.Calculate the height 'B' by subtracting the heights of the bearing seats from the total height.B = 1b - 2a - 2bCarry out this operation on both differential casings which should produce two figures 'Bn' (Height of the new casing) and 'Bv' (Height of the old casing).Subtract the average figure 'Bn' for the new differential casing from the average value 'Bv' for the old casing.The result should be added to the size of the new washer (S2n).This calculation defines the size of the new washer (S2n) which determines the correct pre-loading for the differential internal casing bearings.S2n = S1v + S2v - S1n + (bv - bn)Apply to the shims the increase or decrease previously assigned.This means that the total thickness of both adjustment washers remains constant, as the preload of the differential tapered roller bearings results from it.When determining the thickness, the adjustment shims must be chosen so as to reach the minimum tolerance possible.If they are not worn or obviously damaged, the shims can be used for subsequent adjustments.Fit the differential casing bearings. 2110D26 differential inner case bearings - replace with differential inner case removed