Remove/install complete rear axle

AR35.10-P-0010P

Remove/install complete rear axle

09.03.2020

Model

203

Model

209

except code P98 (Black Series)

6g

Cover

6i

Rear axle spring

6j

Shock absorber

105

Exhaust system

105c

Rear heat shield

106

Propeller shaft

106a

Propeller shaft intermediate bearing

131

Underfloor paneling

131a

Nuts

1c

Screw

6r

Torsion bar

1d

Screw

110c

Intermediate lever housing

2

Electrical connectors

110d

Intermediate lever

6k

Stabilizer bar linkage

111e

Brake hose

 Danger

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

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

AS00.00-Z-0010-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on repair work on suspension components

AH00.00-P-0100-01A

 

Remove/install

1

Shift transmission to position N or to idle.

2

Switch off ignition and store transmitter key outside of transmission range (min. 2  m).

3

Remove seat cushion in rear passenger compartment.

AR91.12-P-1020P

Model 203.0/7
except code 287 (Folding seat backrests in rear passenger compartment)

AR91.12-P-1020PC

Model 209.4
except code P98 (Black Series)

AR91.12-P-1020QA

4

Unhook rear brake cables from intermediate lever (110d) and intermediate lever housing (110c).

 Dismantling tool

*000589956300

5

Secure vehicle on vehicle lift.

AR00.60-P-0100T

6

Remove rear wheels.



AP40.10-P-4050Z

7

Remove rear diagonal struts.

Model 209.4
except code P98 (Black Series)

 Installation: The diagonal struts may only be installed when the vehicle is standing with its wheels on the ground to avoid any strains.

 Self-locking bolt, rear diagonal strut to frame floor

*BA61.10-P-1010-01C

8

Remove exhaust system (105) as from connecting point.

Model 203.035/235/735 with engine 111.951
Model 203.045/245/745 with engine 111.955
Model 203.747 with engine 111.981

AR49.10-P-7000PR

Model 203 with engine 112
Model 209 with engine 112
except code P98 (Black Series)
Model 209.375/475 with engine 113.968
except code P98 (Black Series)
Model 209.376 up to 4/23/04, 209.476 with engine 113.987
except code P98 (Black Series)
Model 209.477 with engine 156.982
except code P98 (Black Series)

AR49.10-P-7000PV

Model 203.004/006/204/206/706 with engine 611.962
Model 203.016/216 with engine 612.962
Model 209.316 with engine 612.967
except code P98 (Black Series)

AR49.10-P-7000PP

Model 203.018/218/718 with engine 612.990

AR49.10-P-7000PF

Model 203 with engine 646
Model 209 with engine 646
except code P98 (Black Series)

AR49.10-P-7000PM

Model 203 with engine 642
Model 209 with engine 642
except code P98 (Black Series)

AR49.10-P-7000PI

Model 203.076/276 with engine 113.988
Model 209.376 as of 4/24/04 with engine 113.987
except code P98 (Black Series)
Model 209.377 with engine 156.982
except code P98 (Black Series)

AR49.10-P-7000AC

Model 203.040/240/740 with engine 271.948
Model 203.042/242/742 with engine 271.940
Model 203.046/246/746 with engine 271.946
Model 203.730 with engine 271.921
Model 203.741 with engine 271.957
Model 209.341/441 with engine 271.955
except code P98 (Black Series)
Model 209.342/442
except code P98 (Black Series)

AR49.10-P-7000QK

Model 203 with engine 271.942
Model 209.3 with engine 271.942
except code P98 (Black Series)

AR49.10-P-7000QD

Model 203.052/252/752 with engine 272.920
Model 203.054/254 with engine 272.940
Model 203.056/256/756 with engine 272.960
Model 203.087/287 with engine 272.970
Model 203.092/292 with engine 272.941
Model 209 with engine 273
except code P98 (Black Series)
Model 209.354/454 with engine 272.940
except code P98 (Black Series)
Model 209.356/456 with engine 272.960
except code P98 (Black Series)

AR49.10-P-7000QB

9

Remove rear heat shield (105c).

10

Remove bolts from propeller shaft intermediate bearing (106a).

AR41.10-P-0050-11DA

 Installation: Mount propeller shaft intermediate bearing (106a) on underbody.

 Bolt, propeller shaft center support bearing to frame floor assembly

*BA41.40-P-1001-01A

11

Remove propeller shaft (106) from rear axle differential, hook up to one side and fix in place.

AR41.10-P-0050-03EA

AR41.10-P-0050-04EA

 Installation: Use new nut.

 Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential

*BA41.10-P-1002-01A

12

Remove torsion bar (6r).

AR32.20-P-0315P

 The torsion bar linkage (6k) remains on the wheel carrier.

13

Remove brake caliper with attached brake hoses (111e) and hook up to one side free of any tension.

AR42.10-P-0080P

14

Disconnect electrical connectors (2) from rear axle rpm sensor on vehicle floor.

15

Remove rear axle springs (6i).

AR32.20-P-0230P

16

Remove shock absorbers (6j) from spring links.

 To do so, remove covers (6g).

 Self-locking nut for attaching shock absorber to spring control arm

*BA32.25-P-1003-03A

17

Unscrew nuts (131a) from underfloor paneling (131).

18

Remove fuel filter from holder.

With exterior fuel filter.

 Do not disconnect fuel lines.

 Hook fuel filter to one side and fix in place.

19

Position lifting platform with mount on rear axle  and secure.



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

20

Remove bolts (1c, 1d).


Do not use an impact wrench.
Otherwise, the threads will be damaged.

 Installation: Use compressed air to clean thread in frame floor assembly and check for correct seating of threaded inserts.

 Use new bolts (1c, 1d).

 Self-locking bolt, front rear axle carrier rubber bushing to frame floor

*BA35.10-P-1001-01A

 Self-locking bolt, rear axle carrier rear rubber bushing to frame floor

*BA35.10-P-1002-01A

21

Lower rear axle and pull slightly towards rear.

Topical note

Notes on cavity preservation

AH97.20-P-0001-01B

 Installation: Check, whether cavity preservation was performed on the rear axle carrier.

If not,



perform cavity preservation.

AR35.10-P-0010-03A



000 588 01 72 00 Sealing and corrosion protection gun

WS97.00-N-0002B

Cavity preservation (free of solvents), 1 liter

*BR00.45-Z-1003-05A

22

Install in the reverse order



Measure

23

Perform chassis alignment.

AR40.20-P-0200P



Check

24

Check headlamp adjustment.



AP82.10-P-8260P

 Rear axle shock absorber

Number

Designation

Model 203

Model 209
except code P98 (Black Series)

BA32.25-P-1003-03A

Self-locking nut for attaching shock absorber to spring control arm

–

Stage 1

Nm

55

50

Stage 2

°

–

–

M10

Nm

–

–

 Rear axle carrier

Number

Designation

Model 203

Model 209
except code P98 (Black Series)

BA35.10-P-1001-01A

Self-locking bolt, front rear axle carrier rubber bushing to frame floor

–

Nm

–

–

With Ø 24 mm bolted flange

Stage 1

Nm

–

–

Stage 2

°

–

–

With Ø 26 mm bolted flange

Stage 1

Nm

40

40

Stage 2

°

90

90

 Rear axle carrier

Number

Designation

Model 203

Model 209
except code P98 (Black Series)

BA35.10-P-1002-01A

Self-locking bolt, rear axle carrier rear rubber bushing to frame floor

–

Nm

–

–

With Ø 24 mm bolted flange

Stage 1

Nm

–

–

Stage 2

°

–

–

With Ø 26 mm bolted flange

Stage 1

Nm

40

40

Stage 2

°

90

90

 Propeller shaft

Number

Designation

Model 203

Model 209

BA41.10-P-1002-01A

Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential

M10

Nm

40

36

M12

Nm

60

58

 Propeller shaft intermediate bearing

Number

Designation

Model 203

Model 209

BA41.40-P-1001-01A

Bolt, propeller shaft center support bearing to frame floor assembly

Self-tapping screw

Nm

–

–

Bolt with washer

Nm

–

–

Bolt with collar and self-centering tip

Nm

30

30

 Frame floor assembly

Number

Designation

Model 209

BA61.10-P-1010-01C

Self-locking bolt, rear diagonal strut to frame floor

Nm

80

Repair materials

Number

Designation

Order number

BR00.45-Z-1003-05A

Cavity preservation (free of solvents), 1 liter

A 000 986 72 70 10