Remove/install rear axle differential

AR35.31-P-0520TX

Remove/install rear axle differential

9.12.09

 

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

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 menu item "SBC Sensotronic Brake Control"/"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

Secure vehicle on the lifting platform

AR00.60-P-0100TX

3

Empty air springs 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: The filling process for the air springs must be observed, otherwise the air springs will be irreparably damaged.

AR32.22-P-1500-03TX



*BA32.25-P-1006-04K



*BA32.25-P-1007-04K



*211589000900



*001589862100



*001589000300

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

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

Model 219.322

AR49.10-P-4951TQ

5

Unhook brake cables from automatic slack adjuster of parking brake

AR42.20-P-0525TX

6

Detach propeller shaft (106) from flange on rear axle center assembly (50)

 Flexible disk remains on propeller shaft.

 Installation: Attach the rear propeller shaft to the rear axle differential.

AR41.10-P-0050-04TX



*BA41.10-P-1002-01E

7

Loosen fitted sleeves of flexible coupling at flange of rear axle center assembly (50)

AR41.10-P-0050-09TX



Drift for loosening fitting sleeves in flex disks.

WF58.50-P-4110-01A

8

Remove rear section of propeller shaft (106)

 Do this by unscrewing bolts from propeller shaft intermediate bearing (106a).

 Installation: Assemble propeller shaft in correct position. 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)

Sheet 266.2

BB00.40-P-0266-02A

9

Remove right rear axle shaft (37)

AR35.30-P-0620TX

10

Remove bolts (41j) and remove left and right additional volume reservoirs (41p) from front center assembly mounting (51)

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



*BA32.22-P-1009-03A

11

Support rear axle center assembly (50) with transmission jack and transmission platform

12

Remove the screw (64b) for the rear center assembly mounting on the rear axle carrier



*BA35.10-P-1004-01J

13

Remove left and right bolts (51a) of front center assembly mounting (51)

 Installation: Ensure that the shims (51b) are correctly positioned. The triangular bulges must point upwards.



*BA35.10-P-1005-01J

14

Lower the rear axle center assembly (50) slightly

15

Pull left rear axle shaft (37) out of rear axle center assembly (50)

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

AR35.30-P-0620-02TX

 Do not damage protective ring (37a). Align bent protective ring (37a) before installing rear axle shaft in order to prevent grinding noises while driving.

 Do not damage radial sealing ring in rear axle differential in order to avoid leaks. Fasten the left rear axle shaft to the frame floor in order not to damage the rubber boot of the rear axle shaft.

 Installation: Replace locking ring (37o) on inner spline profile.

16

Lower rear axle center assembly (50) further

17

Remove bolts (51c) and remove front center assembly mounting (51)



*BA35.10-P-1004-01J

18

Lower rear axle differential (50)

19

Install in the reverse order

20

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

 It is essential to adhere to the work procedure and Specifications for Operating Fluids to avoid damaging the rear axle differential.

AR35.31-P-0520-03TX

 In the interest of better fuel economy, avoid mixing old universal hypoid gear oil with new FE hypoid gear oil.



*BA35.31-P-1002-02D



*BF35.31-P-1003-01P



*BF35.31-P-1004-01P



*BF35.31-P-1005-01P

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

Omnifit sealing compound 100H (50 g)

*BR00.45-Z-1061-01A

21.1

Activate SBC brake system using STAR DIAGNOSIS

Vehicles with Sensotronic Brake Control (SBC)

The following steps should be run through in STAR DIAGNOSIS:

Select "Initial startup after repair"/"Remove/install brake pads" menu item.

Then process all the individual steps from top to bottom.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

 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

Before starting engine, actuate brake pedal several times until the pressure is built up and maintained in the brake system.

AS42.50-Z-0002-01A

21.2

Press the brake pedal several times until the brake pads contact the brake disks

Vehicles with Adaptive Brake (ABR)

 Firm resistance should be noticeable at the brake pedal.

22

Perform a wheel alignment check

AR40.20-P-0200TX

Number

Designation

Model 219 with AIRmatic code 489

BA32.22-P-1009-03A

Bolt, additional volume reservoir to front center assembly mount

Nm

20

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

BA35.10-P-1004-01J

Self-safety bolt, rear axle center assembly at rear at rear axle crossmember

M14 rear

Stage 1

Nm

80

Stage 2

°

60

M10 front

Nm

65

BA35.10-P-1005-01J

Self-locking bolt, front crossmember to rear axle carrier

Stage 1

Nm

80

Stage 2

°

60

Number

Designation

Model
219

BA35.31-P-1002-02D

Oil filler screw, rear axle differential

Nm

50

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 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