Remove/install complete rear axle

AR35.10-P-0010TX

Remove/install complete rear axle

24.7.08

19.6.08

Value changed: Union nut, brake line to brake hose

*BA42.10-P-1001-04I

 

Remove/install

 Danger!

Risk of injury caused by body parts being jammed or crushed. Risk of injury to skin and eyes caused by brake fluid spraying out at high pressure when working on the SBC brake system

Deactivate SBC brake system using STAR DIAGNOSIS.

AS42.46-Z-0001-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 Installation

Caution, important note: The threads in the frame floor assembly must be recut and blown out, as any adhesive residue in a thread will prevent the bolt's necessary preload force from being achieved, despite having reached the specified torque and specified angle of rotation.
If this is not observed, then the faulty bolt preload force will cause bending forces to act on the bolt, which could ultimately lead to bolt fracture.



While working on the rear axle, care must be taken to ensure that the surface of aluminum components do not get any scratches, cracks and notches. Otherwise the service life of the parts will be affected



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

1

Deactivate SBC brake system using STAR DIAGNOSIS.

Vehicles with Sensotronic Brake Control (SBC)

 The following steps should be run through in STAR DIAGNOSIS:

Select the menu item "SBC-Sensotronic Brake Control"/"Initial startup after repair"/"Deactivate 'SBC' system". Then process all the individual steps from top to bottom.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

2

Empty air springs (6i) completely using STAR DIAGNOSIS

Vehicles with AIRmatic (semi-active air suspension), code 489

AR32.22-P-1500-04TX



Notes on AIRmatic

AH32.22-P-1000-02T



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

 Installation: Observe the filling process of the air springs (6i) otherwise they will be destroyed.

AR32.22-P-1500-03TX



*BA32.25-P-1006-04K



*BA32.25-P-1007-04K



*211589000900

Electronic inclinometer
gotis://F_40.2_02.0

3

Secure vehicle on the lifting platform

AR00.60-P-0100TX

4.1

Remove exhaust system at flange connection

Model 219.354 /356 /357 /372

AR49.10-P-7280TX

Model 219.375 /376/ 377

AR49.10-P-7280TY

4.2

Remove rear muffler

Type 219.322

AR49.10-P-4951TQ

5

Remove rear section components on underfloor paneling

AR61.30-P-1001TX

6

Detach propeller shaft (106) from rear axle differential (50)

 The flexible coupling remains on the propeller shaft (106).

 Installation: Attach propeller shaft to rear axle differential (50).

AR41.10-P-0050-04TX



*BA41.10-P-1002-01E

7

Remove fitting sleeves of flexible coupling from rear axle center assembly (50) on the flange

AR41.10-P-0050-09TX



Drift for loosening fitting sleeves in flexible coupling.

WF58.50-P-4110-01A

8

Remove bolts from propeller shaft intermediate bearing (106a) and remove rear part of propeller shaft (106)

 Installation: Assemble propeller shaft (106) in correct order. Only tighten the bolts of the propeller shaft center support bearing (106a) after fastening the flexible coupling on the rear axle differential (50).

AR41.10-P-0050-05TX



*BA41.40-P-1001-01B



Long-life grease (NLGI grade 2)

BB00.40-P-0266-02A

9

Unhook brake cables from automatic slack adjuster of parking brake

AR42.20-P-0525TX

10

Remove rear wheels



Remove/install wheels, rotate if necessary

AP40.10-P-4050TX

11.1

Remove left and right rear brake calipers

For repair work on fuel tank or rear axle.

AR42.10-P-0080TX

 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

11.2

Detach left and right rear brake hose (51) from the brake lines

For bodywork or replacement of rear axle assembly.

AR42.10-P-0013TX

 Installation: The brake hoses (51) must not be twisted after tightening otherwise they may tear.

 Seal off line connections immediately with 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 (51), take care not to twist its bracket. Counterhold open wrench on two flats of brake hose (51) using an open-end wrench.



*BA42.10-P-1001-04I



*000589750300



*129589009100

12

Remove fender liners from rear fenders

Vehicles with AIRmatic (semi-active air suspension), code 489

AR88.10-P-1400TX

13

Disconnect electrical connectors of brake and chassis components at the rear axle

Vehicles with AIRmatic (semi-active air suspension), code 489

AR32.22-P-1500-01TX

14

Remove left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4) from the wheel carriers

Vehicles without AIRmatic

 Unclip electric feed lines of rpm sensor from all retaining clamps and tie up rpm sensor to one side.



*BA42.30-P-1001-02A

15

Disconnect electrical connector from right rear brake pad contact sensor (S10/4)

Vehicles without AIRmatic

16

Detach electrical feed line (1) from right rear brake pad contact sensor (S10/4)

Vehicles without AIRmatic

 Unclip electrical feed line from retaining clamps and tie up to one side.



*BA42.10-P-1002-12B

17.1

Pry left and right air spring (6i) off the frame floor using assembly lever

Vehicles with AIRmatic (semi-active air suspension), code 489

 In doing so the retaining clips for the air springs (6i) are destroyed.

 Installation: Slide on the air springs (6i), until the new clips can be heard engaging into the frame floor. The air springs (6i) must be aligned straight and must not be kinked.

17.2

Remove left and right rear springs

Vehicles without AIRmatic

AR32.20-P-0230TX

18

Detach left and right shock absorbers (6j) from spring control arms

Vehicles with AIRmatic (semi-active air suspension), code 489



*BA32.25-P-1002-03I

19

Drain fuel tank.

Vehicles with diesel engine

AR47.10-P-4001TQ

Vehicles with gasoline engine

AR47.10-P-4001TX

20

Remove filler hose (17) of fuel tank

 Check filler hose (17) and clamps for damage.

21

Install guard plates (01) to protect brake disk cover panels

AR42.00-P-0100-01TX



*220589013100

22

Lower rear axle.

 Do not damage filler hose (17). Kink filler hose (17) downwards when lowering the rear axle.

AR35.10-P-0020-01TX



*BA35.10-P-1001-01J



*BA35.10-P-1002-01J

 Installation: Recut and blow out the threads in the frame floor assembly to ensure a perfect threaded connection.

 Use new bolts.

23

Replace retaining clips of air springs (6i)

Vehicles with AIRmatic (semi-active air suspension), code 489

AR32.22-P-1500-02TX



Checking

24

Check rear axle for damage, replace damaged parts

25

Check condition of air springs (6i)

Vehicles with AIRmatic (semi-active air suspension), code 489

AR32.22-P-1500-05TX

26

Install in the reverse order

27

Check oil level in rear axle center assembly (50) and correct if necessary

 Mixing of old universal hypoid gear oil and the new FE hypoid gear oil should be avoided due to the better fuel economy.

AR35.31-P-0520-03TX



*BA35.31-P-1002-02D



*BF35.31-P-1003-01P



*BF35.31-P-1004-01P



*BF35.31-P-1005-01P

Cleaning spray, Loctite 7063 (150ml)

*BR00.45-Z-1046-04A

Sealant, Omnifit 100H (50 g)

*BR00.45-Z-1061-01A

28.1

Bleed brake system with STAR DIAGNOSIS

Vehicles with Sensotronic Brake Control (SBC)

AR42.10-P-0012TX

 The following steps should be run through in STAR DIAGNOSIS:

Select menu item "initial startup after repair"/"after opening or exchanging one or more brake hoses".

Then process all the individual steps from top to bottom.

 When performing the bleeding operation always observe the instructions in the document "Bleeding brake system using STAR DIAGNOSIS".

28.2

Bleed brake system

Vehicles with Adaptive Brake (ABR)

AR42.10-P-0010T

29

Perform a wheel alignment check

AR40.20-P-0200TX

Number

Designation

Model 219

BA42.30-P-1001-02A

Self-locking bolt of rear axle rpm sensor to wheel carrier

Nm

8

Number

Designation

Model
219

BA41.10-P-1002-01E

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

M12

Nm

60

Number

Designation

Model
219

BA41.40-P-1001-01B

Bolt, propeller shaft intermediate bearing to frame floor assembly

Self-tapping screw

Nm

25

Number

Designation

Model
219
with SBC

Model
219 with
ABR

BA42.10-P-1001-04I

Union nut, brake line to brake hose

Nm

18

18

Number

Designation

Model
219

BA42.10-P-1002-12B

Bolt, brake pad contact sensor to brake caliper

Nm

8

Number

Designation

Model
219

BA35.10-P-1001-01J

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

Stage 1

Nm

90

Stage 2

°

60

BA35.10-P-1002-01J

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

Stage 1

Nm

90

Stage 2

°

60

Number

Designation

Model
219 AIRmatic

BA32.25-P-1002-03I

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

M10

Nm

55

Number

Designation

Model
219

BA35.31-P-1002-02D

Oil filler screw, rear axle differential

Nm

50

Number

Designation

Model
219 with
AIRmatic

BA32.25-P-1006-04K

Nut, rear air spring at spring control arm

Nm

150

BA32.25-P-1007-04K

Air suspension pressure line at rear axle distributor

Nm

5

Number

Designation

Model
219 except 219.376/377

Model
219.376/377

BF35.31-P-1003-01P

Filling capacity

Rear differential assembly dia. 215 mm

Liters

1.2

1.2

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

BB00.40-P-0235-61A

BF35.31-P-1004-01P

Filling capacity

Rear axle differential dia. 198 mm

Liters

1.1

-

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

-

BF35.31-P-1005-01P

Filling capacity

Rear axle center assembly dia. 200 mm

Liters

1.1

-

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

-

Number

Designation

Order number

BR00.45-Z-1061-01A

Sealant, Omnifit 100H (50 g)

A 002 989 23 71

BR00.45-Z-1046-04A

Cleaning spray, Loctite 7063 (150ml)

A 001 986 71 71 10