Remove/install complete rear axle

AR35.10-P-0010CW

Remove/install complete rear axle

09.03.2020

Model

204, 207

Shown on model 204 with code 615 (Bi-xenon headlamps with active light functions) and code 483 (ADVANCED AGILITY package)

01

Guard plate

1

Rear axle

1a

Screw

1s

Screw

2

Stop plate

2a

Bolts

5

Rear axle spring

6h

Bracket

6l

Electric line

8

Spring control arm

9

Shock absorber

50

Rear axle gear

B22/7

Left rear level sensor

L6/3

Left rear axle rpm sensor

L6/4

Right rear axle rpm sensor

 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 self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

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

AH00.00-P-0020-01A

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

Secure vehicle on vehicle lift.

AR00.60-P-0100CW

4

Remove rear wheels.



AP40.10-P-4050CW

5

Remove left and right underfloor paneling.

Model 204, 207

Model 207

AR61.30-P-1001EC

6

Remove left and right rear cross strut.

Model 207.4

 Bolt, rear diagonal strut to spare wheel well

*BA61.10-P-1007-01H

 Bolt, rear diagonal strut to longitudinal member

*BA61.10-P-1008-01H

 Nut/bolt, rear diagonal strut to bracket

*BA61.10-P-1009-01H

7.1

Remove rear muffler.

Model 204 with engine 271, 272, 274, 276, 642, 646, 651
Model 207 with engine 271, 272, 273, 276, 278, 642, 651

Model 204 with engine 271, 272, 274, 276
Model 207 with engine 271, 272, 273, 276, 278

AR49.10-P-7100CW

Model 204 with engine 642, 646, 651
Model 207 with engine 642, 651

AR49.10-P-7100CWI

7.2

Disconnect exhaust system at connecting point to catalytic converter/center muffler and take out.

Model 204 with engine 156

AR49.10-P-7100CW

8

Remove propeller shaft from rear axle differential (50).

AR41.10-P-0050CW

9

Remove rear heat shield above propeller shaft.

10

Disconnect brake cable at connecting point and unclip rear brake cables from holders.

AR42.20-P-0523CW

11

Remove rear axle springs (5).

Model 204
except code P98 (Black Series)
Model 207

AR32.20-P-0230CW

Model 204.3
with code P98 (Black Series)

AR32.20-P-0230CBS

12

Remove shock absorbers (9) from spring links (8).

 Self-locking nut, shock absorber to spring control arm

*BA32.25-P-1001-03M

13

Remove rear axle rpm sensor (L6/3, L6/4) from wheel carriers.

14

Disconnect right rear brake pad wear sensor electrical connector.

15

Remove electrical connector from rear right brake caliper and unclip electric line of rear right brake pad wear sensor from holders on right wheel carrier.

 Screw/bolt, brake wear sensor to brake caliper

*BA42.10-P-1003-12J

16

Disconnect electrical connectors of damping valve units at shock absorbers (9) and unclip electric lines (6l) from holders (6h).

Model 204, 207
with code 483 (ADVANCED AGILITY package)

17

Disconnect electrical connector from left rear level sensor (B22/7) and unclip from holder.

Model 204, 207
with code 615 (Bi-xenon headlamps with active light function)
Model 204, 207
with code 616 (Bi-xenon headlamp unit with integrated asymmetric curve illumination)
Model 204, 207
with code 621 (Bi-xenon adapt. headl., left-s. traffic)
Model 204, 207
with code 622 (Intelligent Light System)
Model 204
with code 614 (Bi-xenon headlamps)
Model 204
with code 618 (Bi-xenon headlamps)

18

Disconnect electrical connectors from right rear level sensor and unclip from holders.

Model 204, 207
with code 483 (ADVANCED AGILITY package)

19

Remove brake caliper with connected brake hoses and hang to one side free of tension.

Model 207

AR42.10-P-0080EW

Model 204 (except 204.077/277/377)

AR42.10-P-0080CW

Model 204.077/277/377

AR42.10-P-0080CMG

20

Support rear axle differential (50) and secure with tensioning strap to prevent it from falling down.



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

21

Attach guard plates (01).

AR42.00-P-0100-01A

 Guard plate

*220589013100

22

Remove screws (1s).

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

 Installation: Clean threads in frame floor assembly using compressed air and recut.
Use new bolts (1s).

 Self-locking bolt of rear elastomer bearing on rear axle carrier to frame floor assembly

*BA35.10-P-1002-01N

23

Unscrew screws (1a, 2a) and remove stop plates (2).

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

 Installation: Clean threads in frame floor assembly using compressed air and recut.
Use new screws (1, 2).

 Self-locking bolt of front elastomer bearing on rear axle carrier to frame floor assembly

*BA35.10-P-1001-01N

 Bolt, stop plate to body

*BA35.10-P-1003-01N

24

Lower rear axle (1).

 Installation: Check whether cavity preservation has been performed on the rear axle carrier.

If not,



perform cavity preservation.

Model 204

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

25

Install in the reverse order



Measure

26

Perform chassis alignment.

Model 204

AR40.20-P-0200CW

Model 207

AR40.20-P-0200EW

 Rear axle shock absorber

Number

Designation

Model 204

Model 207

BA32.25-P-1001-03M

Self-locking nut, shock absorber to spring control arm

Stage 1

Nm

55

55

Stage 2

°

60

60

 Rear axle carrier

Number

Designation

Model 204

Model 207

BA35.10-P-1001-01N

Self-locking bolt of front elastomer bearing on rear axle carrier to frame floor assembly

Stage 1

Nm

80

80

Stage 2

lösen

lösen

Stage 3

Nm

80

80

Stage 4

°

90

90

 Rear axle carrier

Number

Designation

Model 204

Model 207

BA35.10-P-1002-01N

Self-locking bolt of rear elastomer bearing on rear axle carrier to frame floor assembly

Stage 1

Nm

80

80

Stage 2

lösen

lösen

Stage 3

Nm

80

80

Stage 4

°

90

90

 Rear axle carrier

Number

Designation

Model 204

Model 207

BA35.10-P-1003-01N

Bolt, stop plate to body

Nm

30

30

 Rear axle brake caliper

Number

Designation

Model 204

Model 207

BA42.10-P-1003-12J

Screw/bolt, brake wear sensor to brake caliper

Nm

8

8

 Frame floor assembly

Number

Designation

Model 207.4

BA61.10-P-1007-01H

Bolt, rear diagonal strut to spare wheel well

Nm

80

 Frame floor assembly

Number

Designation

Model 207.4

BA61.10-P-1008-01H

Bolt, rear diagonal strut to longitudinal member

Nm

80

 Frame floor assembly

Number

Designation

Model 207.4

BA61.10-P-1009-01H

Nut/bolt, rear diagonal strut to bracket

Nm

17

Repair materials

Number

Designation

Order number

BR00.45-Z-1003-05A

Cavity preservation (free of solvents), 1 liter

A 000 986 72 70 10