B2CG6NK1 - 406D9 BE3 GEARBOX BE4 GEARBOX

REMOVAL - REFITTING DIFFERENTIAL BOX

1 - PRELIMINARY OPERATIONS

Stripping the gearbox .

2 - REMOVAL

Remove :

• the final drive extension (1)

Retrieve :

• the speedometer drive gear (2)
• the O-ring (3)
• the positioning shim (4) (if fitted)

Remove :

• the bolts (6) - (7)

NOTE : the differential housing (7) has notches (A) - (B) making it easier to remove .

Place a screwdriver (8) in the notches (A) - (B) and use as a lever .

Continue to detach the differential housing by tapping on each side using a wooden shim .

Remove :

• the differential housing (7)
• the differential housing (9)

3 - REFITTING

Check that the centralising studs are present (10) .

Check that the joint face is clean .

coat the joint face with a thin, even layer of jointing compound (E15) .

Fit the differential (9) into the housing together with the bearing outer races (11) - (12) .

Fit : The differential housing (7) .

Fit :

• the bolts (5) - (6)

Measure the step X of the extension .

1st fitting - Extension/differential housing (Where projection X of the extension = 10 mm) .

Fit :

• the speedometer drive gear (2)
• the extension (1) fitted with a new O-ring (3)
• the bolts (13) (tightening torque 1.5 ± 0.3 da.Nm)

Tighten :

• the bolts (6) to 5 ± 0.50 da.Nm
• the bolts (5) to 1.25 ± 0.25 da.Nm

2nd fitting - Extension/differential housing (Where projection X of the extension = 8,65 mm) .

Position :

• the bearing adjustment shim [24] on the bearing outer race
• the extension without O-ring

Gradually tighten the extension bolts while turning the differential, until rotation becomes difficult, in order to correctly position the races and bearings .

Remove :

• the differential housing extension
• the adjusting shim

using a depth gauge [33], measure the distance between the joint face and the external bush of the bearing .

Calculation of the thickness of the positioning shim : Y - X + 0,1 mm = Thickness of the positioning shim .

Fit :

• the positioning shim (4)
• the speedometer drive gear (2)
• the extension (1) fitted with a new O-ring (3)

Tighten the bolts (13) to 1.5 ± 0.3 daN.m .

Tighten :

• the bolts (6) to 5 ± 0.5 da.Nm
• the bolts (5) to 1.25 ± 0.25 da.Nm

NOTE : this order of operations ensures correct alignment of the joint faces .

Reassembling the gearbox .