Remove/install front axle

AR33.10-P-0100I

Remove/install front axle

3.5.12

9.8.08

SWZ 140 589 00 33 00 for prying off upper ball joint added

Operation step 3

AR33.20-P-0500-01N

 

Remove/install

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize hydraulic system completely before starting any work on system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A



When working on the front-end assembly, be careful not to scratch, mark or notch the surfaces of aluminum parts. Otherwise the service life of the parts will be affected



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 Installation

Only tighten nuts and bolts of chassis components when vehicle is in a ready-to-drive condition



If there is visible damage, e.g. crack formation or deformation of the front axle carrier (1), these parts must be replaced

1

Deactivate easy entry/exit function

Vehicles with memory package (driver seat, steering column, mirrors) code 275

 Otherwise the driver seat and steering wheel move into a different position if the driver door is opened or closed for example. Damage to the upper frame can occur when the holding device is installed.

 Deactivation is done using the buttons on the steering wheel in the "comfort" menu of the multifunction display; see operator's manual.

2

Turn front wheels to straight-ahead position and secure steering wheel with  holding device

 Swivel sun visor to side and  insert retainer.

 On a disengaged steering coupling (25) the steering wheel should not be turned because the spiral contact coil will be destroyed.



*129589012100

3

Relieve pressure in the front suspension struts (40) using STAR DIAGNOSIS

 The wheels must not touch the ground while filling because the air bellows in the suspension strut (40) will be destroyed if filled with the suspension compressed.

 Installation: Recharge to 5 bar.

4

Suction off oil from expansion reservoir of power steering



*210589007100

5

Remove the front wheels



Remove/install wheels

AP40.10-P-4050Z

6

 Installing protective washers to protect brake disk dust shields

AR42.00-P-0100-01A



*220589013100

7

Disconnect right front axle multiple circuit junction connector, major assembly compartment (X62/6) and left front axle multiple circuit junction connector, major assembly compartment (X62/7)

 Detach connectors for damping valve unit and rpm sensor.

8

Disconnect left front brake pad contact sensor connector (S10/1x1) and right front brake pad contact sensor connector (S10/2x1)

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

9

Unscrew brake lines on the left and right from the brake hoses (39) and seal openings

 Seal off line terminals immediately with  stop plugs. The brake fluid expansion reservoir must not be allowed to run completely empty.

 When loosening or tightening the brake line on the brake hose (39), take care not to twist its bracket. When slackening off and tightening, counterhold with open end wrench on dual flat of brake hose (39).



*000589750300



*129589009100



Brake fluid notes

AH42.50-P-0001-01A



Notes on installing brake hoses

AH42.10-P-9406-01A



*BA42.10-P-1001-04A

10.1

Remove bottom engine compartment paneling

Vehicles with gasoline engine

AR61.20-P-1105M

 Vehicles with fire extinguishing system: Detach pipes in the area of the paneling.

10.2

Remove bottom section of soundproofing

Vehicles with diesel engine

AR94.30-P-5300M

 Vehicles with fire extinguishing system: Detach pipes in the area of the paneling.

11

Press follower joints (8) out of steering knuckles (5)

AR33.20-P-0500-01N



*BA33.20-P-1007-01F



*210589046300



*202589023300



*140589003300

12

Remove bolt (25a) from the steering coupling (25) at the lower steering shaft (80a)

 Installation: Replace locking plate (25f) with self-locking nut.



*BA46.10-P-1001-01E

13

Insert suitable tool in the bore of the steering coupling (25) or in the bore of the lower steering shaft (80a) and pull lower steering shaft (80a) upwards out of the steering coupling (25)

 Do not counterhold at the rubber boot or at the plastic temperature protection disk for the lower steering shaft (80a). Do not use force (hammer blows, excessive leverage) as the lower steering shaft is sensitive to lateral forces.

 Installation: Insert lower steering shaft (80a) all the way into the steering coupling (25); pay attention to the studs of the steering coupling (25) while doing so and the groove of the lower steering shaft (80a) (arrows).

14

Disconnect plug of speed-sensitive power steering (3) from the steering

15

Detach pressure lines at the residual pressure valves (40a) of the suspension struts (40)

 Residual pressure in suspension strut (40) up to 3.5 bar.

If the residual pressure valve (40a) is damaged, replace suspension strut (40).

 Seal off pressure lines during repair work using  stop plugs.

If pressure line connections or pressure lines are damaged: 

AIRmatic compressed-air line.

AR32.22-P-2001-02I



*BA32.25-P-1003-04B



*BA32.25-P-1002-04C



*000589122800



*211589000900



*129589009100

Leak detection spray

*BR00.45-Z-1002-03A

for USA

*BR00.45-Z-1004-03A

16

Detach suspension struts (40) from front end

 Installation: Tighten the fixing nuts in the curb condition.



*BA32.25-P-1001-04B



*BA32.25-P-1001-04C

To replace suspension struts (40):



Remove/install front suspension strut (40).

AR32.25-P-1017I

17

Mount the engine support frame and raise the engine until the front engine mounts are completely relieved of load

Model 220 except 220.028 /128

AR33.10-P-0100-01R

Model 220.028 /128

AR01.10-P-7500-03M

18

Remove bolts (1g) of the front engine mounts on the front axle carrier (1)



*BA22.10-P-1002-03A

19

Support front subframe (1)

AR33.10-P-0100-03I

20

Remove bolts (1f) on front axle carrier (1)

 The bolts (1f) are self-tapping, so the following points must be observed:

 Never recut the thread in the longitudinal member

 Replace screw/bolts

 Use only original screw/bolts (4 x)

 Do not attach bolts at an angle
when screwing in

 Do not use an impact bolt tightener

 Observe tightening torque

 Installation: Before tightening the bolts (1f) center the front axle carrier (1) with a drift (a, 14.8 mm dia.) on the right and left. After this, insert rubber plugs.

 Installation: Model 220.8

Observe spacer plates between the front axle carrier (1) and frame.



*220589001500



*BA33.10-P-1003-01A



Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

21

Detach high-pressure stretch hose (30i) and return pipe (30f) at steering gear

 If necessary lower the front axle slightly, in the process do not tension the lines in order to preclude irreparable damage.

  Seal off line connections using plugs.



*129589009100



*BA46.20-P-1002-01E



*BA46.20-P-1001-01E

22

Remove heat shield from front axle carrier (1)

23

Lower front axle carrier (1)

 Installation: Model 220.8

Note installation position of spacer plates (large plate on front on front-axle carrier (1), small plate to the rear).

24

Remove upper transverse control arm (6)

If necessary

AR33.20-P-0500I



Checking

25

Check front axle carrier (1) for signs of damage and if damage determined replace parts

26

Install in the reverse order

27

Fill power steering pump and bleed

AR46.30-P-0010B

 Danger!

Risk of accident when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work

Depress brake pedal several times before operating vehicle until pressure is built up and maintained in the brake system.

AS42.50-Z-0002-01A

28

Bleed brake system

AR42.10-P-0010I

29

Perform wheel alignment check

Model 215, 220 except 220.875/878

AR40.20-P-0200I

Model 220.875/878

AR40.20-P-0200MP

Number

Designation

Model
220

BA22.10-P-1002-03A

Front engine mount on front axle carrier

Nm

35

Number

Designation

Model
220.025/026/028/063/
065/067/070/073/074/
075/125/126/128/163/
165/167/170/173/174/
175/176/178/179

BA32.25-P-1001-04B

Nut, front suspension strut to front end

Nm

20

BA32.25-P-1003-04B

Air suspension pressure line to front suspension strut

Nm

5

Number

Designation

Model 220.875/
878

BA32.25-P-1001-04C

Nut, front suspension strut to front end

Nm

20

BA32.25-P-1002-04C

Air suspension pressure line to front suspension strut

Nm

5

Number

Designation

Model
220

BA33.10-P-1003-01A

Bolt, front axle carrier to front end

Nm

100

Number

Designation

Model
220

BA42.10-P-1001-04A

Brake pipe to brake hose

Nm

14

Number

Designation

Model
220 without code Z07 except model 220.08/18 /8

Model 220.875/
878

BA33.20-P-1007-01F

Self-locking nut, upper ball joint out of upper transverse control arm to steering knuckle

Stage 1

Nm

20

20

Stage 2

°

90

90

Number

Designation

Model
220.025/026/
028/063/065/
067/070/073/
074/075/125/
126/128/163/
165/167/170/
173/174/175/
176/178/179/
875/878

BA46.10-P-1001-01E

Bolt, steering coupling to steering shaft

Stage 1

Nm

30

Stage 2

°

-

Number

Designation

Model
220.025/026/
028/063/065/
067/070/073/
074/075/125/
126/128/163/
165/167/170/
173/174/175/
176/178/179/
875/878

BA46.20-P-1001-01E

Return pipe to rack-and-pinion steering

Nm

45

BA46.20-P-1002-01E

High-pressure stretch hose to rack-and-pinion steering

Nm

40

Number

Designation

Order number

BR00.45-Z-1002-03A

Leak detection spray

Christof Fischer GmbH,
Augsburger Str. 289-293,
70327 Stuttgart
Germany
Tel. +49 711 30502-0
Fax +49 711 30502-10
www.kaeltefischer.de

BR00.45-Z-1004-03A

Leakage spray for USA

LIQUI MOLY
Gary Boyd
1820 Clark Avenue

Long Beach, CA 90815
USA
Tel. +1 562 5975519

Fax + 1 562 5975269
www.liqui-moly.com