G Class Differential Locks
1
327 HO 08 W463 Diff Locks (AB IC TF) 03-01-04
Objectives
1. 2. 3. 4. 5. 6. 7. 8. At the end of this presentation, you should be able to: Explain the function of and purpose for differential locks Describe the customer operation of differential locks List the vacuum components used for differential locks Describe the operation of pressure intensifier units List the hydraulic components used for differential locks Describe what happens in the axle shift cylinder List the mechanical axle locking elements Explain maintenance necessary for the differential lock hydraulic circuit
These technical training materials are current as of the date noted on the materials, and may be revised or updated without notice. Always check for revised or updated information. To help avoid personal injury to you or others, and to avoid damage to the vehicle on which you are working, you must always ref er to the latest Mercedes -Benz Technical Publication and follow all pertinent instructions when testing, diagnosing or making repair. Illustrations and descriptions in this training reference are based on preliminary information and may not correspond to the final US version vehicles. Refer to the official introduction manual and WIS when available. Copyright Mercedes-Benz USA, LLC, 2004 WIS document numbers shown apply to WIS Version USA/CDN at date of writing. Reproduction by any means or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Mercedes -Benz USA, LLC or it's successors. Published by Mercedes -Benz USA, LLC Printed in U. S.A.
Contents
Purpose of Differential Locks When to use Differential Locks Engaging Differential Locks Vacuum components and operation Pressure intensifier units Hydraulic circuit Axle shift cylinder Mechanical axle locking elements Maintenance 4 5 6 9 14 16 17 18 21
Purpose of Differential Locks
An open differential allows the driven wheels to turn at different speeds when turning a corner. In off-road conditions one or several wheels can lose traction. The differential allows the torque to go to the wheels that are easiest to turn. Result: spinning wheels !! A differential lock secures one axle shaft to the rotating differential case. The differential spider gears can no longer allow a difference in speed, both axle shafts turn at the same speed.
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When To Use Differential Locks
Differential locks should be engaged for traction improvement while:
3 1 2
Driving off-road Fording Driving on snowy, icy or muddy non-paved surfaces
In Order:
1 - Center lock switch 2 - Rear lock switch 3 - Front lock switch
Engaging differential locks while on paved roads can damage drivetrain components.
Engaging Differential Locks
Fixed sequence (cannot be changed) - center, rear, front Lock request: Yellow indicator MF Display: ESP NOT AVAILABLE Lock confirmation: Red indicator MF Display: ESP NOT AVAILABLE ABS NOT AVAILABLE BAS NOT AVAILABLE
Note: MY2002 Multifunction warning display shown
2003 MF Display
Lock engaged Lock requested
Warning display changed for 2003 due to NHTSA mandate
Differential Lock Switch Group (S76)
Task: Activates the individual differential lock Monitors differential lock engagement Ensures engagement sequence Indicates condition - off, request or engaged Time delay - ensures differential locks stay engaged for ~ 30 seconds when ignition switched off Inputs: Differential lock confirmation switches 58d lighting Outputs: Differential lock relay Front & rear differential lock switchover valves ESP
No self-diagnostics Guided test available in SDS / DAS
Hydraulic Reservoir
Vacuum and Hydraulic Diagram
Manifold Vacuum
Vacuum Pump
Vacuum Reservoir
Rear Axle Differential Lock Cyl.
Rear Intensifier
Front Intensifier
Center differential Lock
Front Axle Differential Lock Cyl.
Vacuum center differential lock Vacuum / Hydraulic front & rear differential lock Check valves on center & rear vacuum supply
Differential Lock Switchover Valves
Rear diff. Lock (Y68/1)
Front diff. Lock (Y68/2)
Center diff. Lock (Y68)
Location: mounted on the firewall right of the brake booster
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Pressure Intensifier Units
Task: Convert vacuum to hydraulic Provide hydraulic pressure
From fluid reservoir Breather Front axle
Rear axle
Driving direction
from switchover valves
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Location: inside of left frame rail
Pressure Intensifier Unit
Function: Vacuum is applied to a large area diaphragm Diaphragm and hydraulic piston are pulled in a downward direction Downward movement of the piston creates hydraulic pressure of approximately 15 bar When vacuum is removed the spring force will return the diaphragm and hydraulic piston to its rest position
Pressure Intensifier (pneumatic system-hydraulic system) 1. vent 2. hydraulic reservoir 3. Shift cylinder 4. vacuum 12
Hydraulic Circuit
Differential lock reservoir
~0.4 bar vacuum from switch over valve
Pressure intensifier unit
Shift cylinder
~15.0 bar hydraulic pressure
axle circuit illustrated
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Hydraulic Reservoir
Vacuum and Hydraulic Diagram
Manifold Vacuum
Vacuum Pump
Vacuum Reservoir
Rear Axle Differential Lock Cyl.
Rear Intensifier
Front Intensifier
Center differential Lock
Front Axle Differential Lock Cyl.
Vacuum center differential lock Vacuum / Hydraulic front & rear differential lock Check valves on center & rear vacuum supply
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Axle Shift Cylinder
8 7 6 5 4 3 2 1
1 End cover with bleeder nipple 2 Gasket 3 Shift piston 4 Spring 5 Shaft 6 Compression spring 7 Lever 8 Shift sleeve 9 Confirmation switch 10 Shift cylinder
10
Hydraulic force moves the shift piston Piston movement causes mechanical movement of the shaft and lev er Switch S76/8,9 confirms lever at end stop (engaged)
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Mechanical Axle Locking Elements
7 5 6
1. Shift cylinder 2. Axle tube 3. Joint housing 4. Center drive
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5. Shift sleeve 6. Shift tube 7. Polyamide ring
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P33.30-0357-05
Axle Differential Lock-Disengaged
Shift sleeve not engaged with center drive
17
Axle Differential Lock-Engaged
Hydraulic pressure
Adjust shift cylinder position when lock is engaged with hydraulic pressure Shift lever can be bent if engaged while wheel slipping If shift lever bent or incorrectly adjusted the switch will not be operated
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Maintenance
Every A & B service: Check & correct fluid level DOT 4 Plus brake fluid Engage differential locks for short distance, then unlock (AP29.00-P-2912G) Replacement of fluid could be done as a preventative measure every 3 - 5 years
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Maintenance
The WIS job number for bleeding the front and rear differential locks is AR33.40-P-0701GG.
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