Procedures
2110D20 DIFFERENTIAL INNER CASE, REMOVED - DISMANTLE AND REBUILD, CHECK PLANET AND DIFFERENTIAL GEARS
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
Removing
- Remove the mileometer gear.1. Remove the roller bearing (1a), differential side, using tools (1b), (1c) and (1d).| [symbol: TOOLS 10.jpg] | Description | Code | Function |
|---|---|---|---|
| 1b | Reaction flange for removing differential bearings | 1.860.944.000 | Removing differential bearings |
| [symbol: TOOLS 11.jpg] | Description | Code | Function |
|---|---|---|---|
| 1c | Leg for differential bearing removal tool 1840005001. | 1.840.005.309 | Removing differential bearings |
| [symbol: TOOLS 12.jpg] | Description | Code | Function |
|---|---|---|---|
| 1d | Universal extractor for removing layshaft front bearing and differential bearings | 1.840.005.001 | Removing differential bearings |
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Remove the roller bearing (1a), ring gear side, using tools (1b), (1c) and (1d).
| [symbol: TOOLS 13.jpg] | Description | Code | Function |
|---|---|---|---|
| 1b | Reaction flange for removing differential bearings | 1.860.944.000 | Removing differential bearings |
| [symbol: TOOLS 14.jpg] | Description | Code | Function |
|---|---|---|---|
| 1c | Universal extractor for removing layshaft front bearing and differential bearings | 1.840.005.001 | Removing differential bearings |
| [symbol: TOOLS 15.jpg] | Description | Code | Function |
|---|---|---|---|
| 1d | Leg for differential bearing removal tool 1840005001. | 1.840.005.309 | Removing differential bearings |
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the fixing bolts (1a) and remove the ring gear (1b).
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Remove the upper differential gear.
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Remove the planet carrier pin.
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Remove the planet wheels (1a) and the lower differential gear (1b).
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Separate the ring gear (1a) from the differential half-casing at the press (1b).
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
Refitting
1. Tighten the retaining bolts to locate the ring gear on the differential half-casing correctly.2. Fit the ring gear (2a) to the differential casing on the press (2b).
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Fit shim (1b) and lower differential gear (1c) in the seat in the differential half-casing (1a).
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Fit planet carrier pin (1b) and planet gears (1c) into the differential half-casing (1a).
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Position a dial gauge (1a) with a magnetic base so that its probe is in contact with the differential gear flat circular ring gear (1b).- Set the dial gauge to zero.
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Introduce a screwdriver into the hole on the driveshaft and remove the differential gear.- Check the clearance is within specificed limits.
- Otherwise, fit an appropriate shim.
| [symbol: MEASURE 01.jpg] | Subject | Value |
|---|---|---|
| - | - | mm <0.1 |
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
- Fit the pin mount, short pins, missing planet gears and the upper differential gear with its shim to the seat in the differential half-casing.1. Secure the differential gear (1a) using tools (1b) and (1c).
| [symbol: TOOLS 16.jpg] | Description | Code | Function |
|---|---|---|---|
| 1b | Leg for differential bearing removal tool 1840005001. | 1.840.005.309 | Fitting the upper differential gear |
| [symbol: TOOLS 17.jpg] | Description | Code | Function |
|---|---|---|---|
| 1c | Reaction flange for removing differential bearings | 1.860.944.000 | Fitting the upper differential gear |
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Position a magnetic base dial gauge (1a) to the flange with the gauge probe in contact with the shim (1b).2. Fit tools (2a), (2b), (2c).
- Set up the dial gauge and zero.
| [symbol: TOOLS 18.jpg] | Description | Code | Function |
|---|---|---|---|
| 2a | Feet for 1040005001 | 1.840.005.309 | Removing the layshaft front bearing |
| [symbol: TOOLS 19.jpg] | Description | Code | Function |
|---|---|---|---|
| 2b | Universal extractor for removing the layshaft front bearing and differential bearings | 1.840.005.001 | Removing the layshaft front bearing and differential bearings |
| [symbol: TOOLS 20.jpg] | Description | Code | Function |
|---|---|---|---|
| 2c | Reaction flange for removing differential bearings | 1.860.944.000 | Removing differential bearings |
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Position the calibrated dial gauge on the other differential half-casing and check that the clearance is within specified limits.
- Otherwise, fit an appropriate shim.
| [symbol: MEASURE 02.jpg] | Subject | Value |
|---|---|---|
| - | - | mm <0.10 |
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
- Tighten the bolts securing the ring gear to the differential casing to the specified torque.
1. Use tool (1a) to fit the taper roller bearing (1b), ring gear side.
| [symbol: TORQUE 09.jpg] | Value - daNm | Fastening | Component | Ø |
|---|---|---|---|---|
| 8,5 | bolt | - | - |
| [symbol: TOOLS 21.jpg] | Description | Code | Function |
|---|---|---|---|
| Fit the differential bearings | 1.860.943.000 | Fit the differential bearing, ring gear side |
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Use tool (1a) to fit the taper roller bearing (1b), differential side.
| [symbol: TOOLS 22.jpg] | Description | Code | Function |
|---|---|---|---|
| Fit the differential bearings | 1.860.943.000 | Fit the differential bearing, ring gear side |
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
- Fit the mileometer gear.