Remove/install front axle transmission

AR33.30-P-0525P

Remove/install front axle transmission

10.11.11

29.11.07

Value changed: bolted connection, rack-and-pinion steering to front axle carrier, 1st stage

*BA46.20-P-1002-01F

Value changed: bolted connection, rack-and-pinion steering to front axle carrier, 2nd stage

*BA46.20-P-1002-01F

Value changed: Threaded connection, retaining plate to front axle carrier, 1st stage

*BA46.20-P-1004-01F

Value changed: Threaded connection, retaining plate to front axle carrier, 2nd stage

*BA46.20-P-1004-01F

 

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 caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0011-01A



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A

1

Open engine hood

AR88.40-P-1000P

2

Remove left and right intake air duct (7) upstream of air filter

3.1

Detach air filter housing from above vertically from the cylinder head covers

Model 203 with engine 112

 Installation: Moisten slightly with antifriction agent the rubber retainers on the cylinder head covers and the sealing ring of the hot film mass air flow sensor in the air filter housing.

Lubricant paste

*BR00.45-Z-1002-06A

3.2

Remove air filter housing

Model 203 with engine 272

AR09.10-P-1150QB

4

Loosen bolt (4) on exhaust shielding plate (2) for propeller shaft of front axle gear

Model 203 with engine 272

5

Mount engine support bracket and raise engine slightly

AR33.10-P-0100-01P

Engine support device, engine hoist
gotis://A_01_09.0

6

Detach return line of rack-and-pinion steering from the top of the front axle carrier (1)

 Nuts between the engine and radiator and nut in front of the right-hand engine mount.

7

Raise vehicle

AR00.60-P-1000P

8

Detach front and rear lower engine compartment paneling

AR61.20-P-1105P

9

Detach return line of rack-and-pinion steering from the bottom of the front axle carrier (1)

 The nut is located in front of the steering coupling.

10

Remove right and left front axle shaft (60)

AR33.30-P-0620P

11

Remove intermediate shaft (34)

AR33.30-P-0625P

12

Detach torsion bar (77) on left and right of the link rods (78)



*BA32.20-P-1002-02B

13

Detach the exhaust shielding plate (1k) above the right rubber boot of the rack-and-pinion steering

14

Remove retaining panel (1h) of rack-and-pinion steering



*BA46.20-P-1002-01F



*BA46.20-P-1004-01F

15

Pull rack-and-pinion steering slightly backwards and tie in place

16

Remove right O2 sensor downstream of CAT (G3/6)

Model 203 with engine 272

AR07.52-P-5303QB

17

Unclip electrical feed line of O2 sensor from retaining clamps (6)

Model 203 with engine 272

18

Undo bolt (3) and nut (5) and remove exhaust shielding plate (2)

Model 203 with engine 272



*BA33.30-P-1001-03D

19

Mark front axle gear propeller shaft (70) in relation to front axle gear flange

20

Detach front axle gear propeller shaft (70) from front axle gear flange

 Installation: Observe marking.

 Counterhold propeller shaft of front axle gear (70) using counterholder.

 Counterholder

*203589004000



*BA33.30-P-1004-02C

21

Tie front axle gear propeller shaft (70) to one side.

22

Detach the left and right engine mount at the bottom of the front axle carrier

 Model 203 with engine 112

*BA22.10-P-1001-01R

 Model 203 with engine 272

*BA22.10-P-1001-01S

23

Remove headlight range control's linkage rod from lower control arm.

Model 203 with engine 272

24

Support front subframe (1)

AR33.10-P-0100-03P

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

25

Remove bolts (1f) of front axle carrier (1).

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

 Never retap the thread in the side member

 Replace screws (1f).

 Use only original bolts (4 x)

 Do not insert bolts (1f) at an incline when turning in

 Do not use an impact bolt tightener

 Observe tightening torque



*BA33.10-P-1003-01A

26

Lower front subframe (1)

 Secure front axle carrier (1) against falling

27

Detach exhaust shielding plate (69) for front axle gear propeller shaft (70)

Model 203 with engine 112



*BA33.30-P-1001-03D

28

Detach mounting support of front axle gear (58)



*BA33.30-P-1001-03D

29

Detach high-pressure line of rack-and-pinion steering from the oil pan

Model 203 with engine 112

30

Insert drift into radial sealing ring on outside right of front axle gear (50)

 To prevent transmission fluid from escaping from the hole during removal.



*210589011500

31

Detach front axle gear (50) and remove

 Four bolts from the left and two from the right.

 Ensure that no transmission oil escapes.



*BA33.30-P-1002-03D

32

Install in the reverse order

33

Check front axle gear oil level, refill if necessary

AR33.30-P-0525-02P



*BF33.30-P-1001-03C



*BA33.30-P-1006-03D

34

Read out fault memory with STAR DIAGNOSIS and erase if necessary

STAR DIAGNOSIS diagnosis system



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

Number

Designation

Engine
112.916/
953
in model 203

BA22.10-P-1001-01R

Bolt, front engine mount to front axle carrier

Nm

35

Number

Designation

Engine 272
in model 203
with 4-MATIC

BA22.10-P-1001-01S

Bolt, front engine mount to front axle carrier

Nm

35

Number

Designation

Model 203.08/09/28/29

BA32.20-P-1002-02B

Self-locking nut, connecting rod to torsion bar

M10

Nm

55

M101.5

Nm

-

M121.5

Nm

-

M141.5

Nm

-

Number

Designation

Model
203

BA33.10-P-1003-01A

Bolt, front axle carrier to front end

Nm

100

Number

Designation

Model
203.08/09/28/29

BA33.30-P-1004-02C

Bolt, front axle gear propeller shaft to front axle gear flange

M8

Stage 1

Nm

15

Stage 2

°

60

M10

Stage 1

Nm

-

Stage 2

°

-

Number

Designation

Model
203.08/09/
28/29

BA33.30-P-1001-03D

Collar bolt connecting mounting support to front axle final drive and engine mount carrier

Nm

22

BA33.30-P-1002-03D

Collar bolt of front axle gear to engine oil pan

Nm

65

BA33.30-P-1006-03D

Oil filler opening screw plug

Nm

30

Number

Designation

Model
203

BA46.20-P-1002-01F

Bolted connection, rack-and-pinion steering to front axle carrier

Stage 1

Nm

50

Stage 2

°

90

BA46.20-P-1004-01F

Bolted connection, supporting plate to front axle carrier

Stage 1

Nm

50

Stage 2

°

60

Number

Designation

Model
203.08/09/28/29

BF33.30-P-1001-03C

Hypoid gear oil

Filling capacity

Liters

0,46

Specifications for service products

Sheet

BB00.40-P-0235-07A

Number

Designation

Order number

BR00.45-Z-1002-06A

Antifriction paste, rubber parts 2.5 kg, DB supply specification 6867.00

A 000 989 01 60