10-31-2014, 04:43 PM
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1979 & 1985 300D's
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Join Date: Oct 2012
Location: Tucson, AZ
Posts: 1,097
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Here is a description I wrote for a friend a while back to boil down the steps. That DIY is pretty long, maybe this helps give perspective. It's not a bad job.
- Raise car
- Remove wheels
- Remove calipers from rear wheel carriers, hang them up (for extra working room)
- Drain diff fluid
- Support the rear diff with a floor jack
- Unbolt the diff mount from the diff cover, then unbolt the mount from the body and remove it
- Lower the diff down a bit for easier access to all eight cover bolts, remove bolts and pull off cover
- Hang axles with some wire to the sway bar to keep them from dropping
- Unbolt axle at wheel hub, single 13mm bolt
- Tap the axle out of the hub with a brass drift
- Pull the c-clip off the other end of the axle inside the diff
- Pull axles out, retain the spacer rings on the inside end, don't mix them up the spacer rings need to stay on their respective sides - note when removing the axles it helps to lift the diff up about as high as you can go
- Pull diff side seals out with a seal puller
- Press in new seals
- Put spacer rings on the new axles on their respective sides
- Push the axle in to the diff first, inserting the c-clip to keep it from moving out again, then work the opposite end in to the hub as far as possible by hand
- Then use the bolt to pull it in the last bit of the way
- Clean up the surfaces on the cover and body of the diff, then run a bead of RTV all the way around the cover. Follow the directions on the RTV about set up time, etc. The one I used said to install the cover right away (no skin-over time), but only finger tight, and wait 1 hour to torque it down. Then let it cure 24 hours before putting in any fluids.
- Torque diff cover bolts, install mount to cover, then lift the diff up to bolt it to the mounts to the body of the car
- Reinstall calipers
- Check torque on all bolts
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