3026029 - 2110D20 differential inner case, removed - dismantle and rebuild, check planet and differential gears

1. Remove the two bearings (1a) from the inner differential housing using tools (1b) and (1d).

	Name	Country
1b	Extractor	1.840.005.200

	Name	Country
1c	Clamps	1.840.005.103

.

The speedometer drive gear is fitted on the differential even if it is not used.

1. Remove the speedometer drive gear (1a) using a reaction washer and tools (1b) and (1c).

	Name	Country
1b	Extractor	1.840.005.200

	Name	Country
1c	Clamps	1.840.005.103

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 pin (1a) using a suitable drift.

The circlip (1b) will be cut during this operation.

2. Extract the satellite gears (2a) and the washers (2b).3. Remove the planet gears. Check that the satellite and planet gears are intact and that there are no signs of seizing.Place the planet gears back in their housings.Place the satellite gears back in their housings with the non-slip washers.Place the satellite carrier pin back in its housing using a suitable drift.Place a new flexible retaining in for the satellite carrier pin back in its housing using a suitable drift.Use a screwdriver to check that the differential planet gears fit together properly. Ensure that they turn without play and with slight resistance.Place the ring gear back in its housing checking the marks made during the dismantling and secure it by tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	DIFF CROWN WHEEL	M10	7.9 ÷ 9.7

Place the speedometer drive gear back in its housing after having heated it to a temperture of 100 to 120 degrees C.1. Fit bearings (1a) in the inner differential housing using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.062.000

Dismantling ( Reassembling ) Position the differential internal housing in the vice fitted with protective jaws.1. Remove the front bearing (1a) using tools (1b) and (1c).

	Name	Country
1b	Extractor	1.840.005.001

	Name	Country
1c	Clamps	1.840.005.301

2. Remove the speedometer drive gear. 1. Remove the rear bearing (1a) using tools (1b) and (1c).

	Name	Country
1b	Extractor	1.840.005.001

	Name	Country
1c	Clamps	1.840.005.301

1. Undo the bolts (1a) and remove the ring gear (1b). 1. Separate the halves of the differential internal housing using a suitable drift.2. Remove the adjustment shim.3. Remove the bearing.4. Remove the differential gear. 1. Remove the planet carrier shaft retaining pin using a suitable drift. 1. Remove the planet carrier shaft using a suitable drift.2. Remove the planet gears (2a) and thrust washers (2b).3. Remove the differential gear.4. Remove the bearing.5. Remove the adjustment shim. Reassembling ( Dismantling ) Place the adjustment shim in its seating in the front differential half case.Refit the bearing back in its seating.Refit the planet gear in its seating.Fit the satellite gears and thrust washers and fix them with the satellite carrier shaft to be fitted using a suitable drift.Fit the satellite carrier shaft retaining pin using a suitable drift.1. Position the front half of the differential housing using a special gauge.2. Fit the gauge to the differential front half-casing.3. Position a magnetic base (3a), complete with dial gauge (3b), with the pointer in contact with the tool and a pre-loading of 1 mm.Rotate the tool and move it axially, checking that the end float is within the recommended values.

	Measurement		Value
-	End float (mm)		0.2

If the values measured do not correspond with the figures given, replace the scraper ring with a suitably sized one.Rotate the tool through one complete revolution and check that the variation in the end float is within the recommended values.

	Measurement		Value
-	End float minimum variation (mm)		0.1

Refit the planet gear in its seating.Refit the bearing back in its seating.Place the adjustment shim back in its housing.Place the rear half-case in its seating.1. Place the differential crownwheel (1a) in its seating and fix it temporarily with its bolts (1b).2. Place the gauge on the rear differential half-case.3. Position a magnetic base (3a), complete with dial gauge (3b), with the pointer in contact with the tool and a pre-loading of 1 mm.Rotate the tool and move it axially, checking that the end float is within the recommended values.

	Measurement		Value
-	Max. end float. (mm)		0.2

If the values measured do not correspond with the figures given, replace the scraper ring with a suitably sized one.Rotate the tool through one complete revolution and check that the variation in the end float is within the recommended values.

	Measurement		Value
-	End float minimum variation (mm)		0.1

Tighten the differential crown wheel bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	DIFF CROWN WHEEL	M10	8.1 ÷ 9.9

Place the speedometer drive gear back in its seating.1. Fit the front bearing (1a), using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000

1. Place the rear bearing (1a) back in its housing using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000

Dismantling ( Reassembling ) Position the differential internal housing in the vice fitted with protective jaws.1. Remove the front bearing (1a) using tools (1b) and (1c).2. Remove the speedometer drive gear.

	Name	Country
1b	Extractor	1.840.005.200

	Name	Country
1c	Clamps	1.840.005.103

1. Remove the rear bearing (1a) using tools (1b) and (1c).

	Name	Country
1b	Extractor	1.840.005.200

	Name	Country
1c	Clamps	1.840.005.103

1. Undo the bolts (1a) and remove the ring gear (1b). 1. Separate the halves of the differential internal housing using a suitable drift.2. Remove the adjustment shim.3. Remove the bearing.4. Remove the differential gear. 1. Remove the planet carrier shaft retaining pin using a suitable drift. 1. Remove the planet carrier shaft using a suitable drift.2. Remove the planet gears (2a) and thrust washers (2b).3. Remove the differential gear.4. Remove the bearing.5. Remove the adjustment shim. Reassembling ( Dismantling ) Fit the scraper ring in the front half of the differential housing.Fit the bearing.Fit the differential gear.Fit the planet gears and thrust washers and fix them with the planet carrier shaft to be fitted using a suitable drift.Fit the planet carrier shaft retaining pin using a suitable drift.1. Position the front half of the differential housing using a special gauge.2. Fit the tool on the front half of the differential housing.

	Name	Country
2	Gauge	1.820.125.000

3. Position a magnetic base (3a), complete with dial gauge (3b), with the pointer in contact with the tool and a pre-loading of 1 mm.Rotate the tool and move it axially, checking that the end float is within the recommended values.

	Measurement		Value
-	End float (-)		0.2

If the values measured do not correspond with the figures given, replace the scraper ring with a suitably sized one.Rotate the tool through one complete revolution and check that the variation in the end float is within the recommended values.

	Measurement		Value
-	End float variation (-)		0.1

Fit the differential gear.Fit the bearing.Fit the adjustment shim.Fit the rear half of the housing.1. Fit the ring gear (1a) and fix it temporarily using the bolts (1b).2. Fit the tool A on the rear half of the differential housing.

	Name	Country
2	Gauge	1.820.125.000

3. Position a magnetic base (3a), complete with dial gauge (3b), with the pointer in contact with the tool and a pre-loading of 1 mm.Rotate the tool and move it axially, checking that the end float is within the recommended values.

	Measurement		Value
-	End float (-)		0.2

If the values measured do not correspond with the figures given, replace the scraper ring with a suitably sized one.Rotate the tool through one complete revolution and check that the variation in the end float is within the recommended values.

	Measurement		Value
-	End float variation (-)		0.1

Tighten the differential crown wheel bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	DIFF CROWN WHEEL	M10	7.7 - 9.5

Fit the speedometer drive gear.1. Fit the front bearing (1a), using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000

1. Fit the rear bearing (1a), using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000