Boot cap on joint ring removal and installation

AR35.30-P-0661-01P

Boot cap on joint ring removal and installation

Model

166, 170, 171, 172, 203, 204, 207, 208, 209, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 292

 Rear axle shaft

Number

Designation

Model 203.004/006/007/008/016/018/035/045/061/065/076/081/084/087/092/204/206/207/208/216/218/235/245/261/265/276/281/284/287/292/706/707/708/718/735/745/747
Rear axle shaft (inserted)

Model 203.004/006/018/035/045/061/065/081/084/087/092/204/206/218/235/245/261/265/281/284/287/292/706/718/735/745
Rear axle shaft (bolted on)

BF35.30-P-1001-01D

Filling capacity

Inner constant velocity joint

g

–

120

 Rear axle shaft

Number

Designation

MODEL 203.007/207 with TRANSMISSION 716 Bolted-on rear axle shaft except CODE 450, MODEL 203.707 with TRANSMISSION 711, 716 Bolt-on rear axle shaft except CODE 450

MODEL 203.007/207/707 with TRANSMISSION 722 Bolted-on rear axle shaft except CODE 450

BF35.30-P-1001-01D

Filling capacity

Inner constant velocity joint

g

100

85

 Rear axle shaft

Number

Designation

MODEL 203.007/207 with TRANSMISSION 716 Bolted-on rear axle shaft with CODE 450, MODEL 203.008/208 with TRANSMISSION 716 Bolt-on rear axle shaft, MODEL 203.708 with TRANSMISSION 711, 716 Bolted-on rear axle shaft

MODEL 203.007/207 with TRANSMISSION 722 Bolted-on rear axle shaft with CODE 450, MODEL 203.008/016/208/216/708 with TRANSMISSION 722 Bolted-on rear axle shaft

BF35.30-P-1001-01D

Filling capacity

Inner constant velocity joint

g

120

105

 Rear axle shaft

Number

Designation

Model 203.016/216 with transmission 716
Rear axle shaft (bolted on)

Model 203.076/276
Rear axle shaft (bolted on)

BF35.30-P-1001-01D

Filling capacity

Inner constant velocity joint

g

150

150

 Rear axle shaft

Number

Designation

Model 203.747 with transmission 716
Rear axle shaft (bolted on)

Model 203.747 with transmission 722
Rear axle shaft (bolted on)

BF35.30-P-1001-01D

Filling capacity

Inner constant velocity joint

g

100

85

 Rear axle shaft, plugged in shafts

Number

Designation

Model 166, 170, 171, 172, 204, 207, 208, 209, 211, 212, 215, 216, 218, 219, 220, 221, 230, 246, 292
Plugged in shafts

Model 217
Plugged in shafts

BF35.30-P-1001-01G

Filling capacity for joint housing

Ø82

g

80

80

Ø95

g

100

100

Ø102

g

120

120

Ø106

g

130

130

Ø112

g

140

140

Ø116

g

150

150

 Rear axle shaft, plugged in shafts

Number

Designation

Model 222
Plugged in shafts

Model 231
Plugged in shafts

BF35.30-P-1001-01G

Filling capacity for joint housing

Ø82

g

80

80

Ø95

g

100

100

Ø102

g

120

120

Ø106

g

130

130

Ø112

g

140

140

Ø116

g

150

150

1

Using protective jaw pads, clamp rear axle shaft into vise.

2

Using a hand coping saw, saw cup seal (37i) radially in the groove on the press-in edge so that a notch arises.

 Saw carefully.
The joint ring (37c) will otherwise be damaged.

3

Use a screwdriver to lift the notched area.

37c

Joint ring

4

Starting at the standing away end, unscrew cup seal (37i) using suitable pliers until it is possible to lift the cup seal (37i) off the joint ring (37c).

 When unscrewing the cup seal (37i) ensure that the rear axle shaft does not fall out of the joint ring (37c) before the parts have match marks placed.

5

Mark installation position of rear axle shaft relative to joint ring (37c).

6

Remove clamp (37k).

7

Pull boot with boot cap (37i) from joint ring (37c) and slide down rear axle shaft.

 If both boots are to be replaced, the boot opposite can be slid over the rear-axle shaft.

8

Replace O-ring on joint ring (37c).

 Do not oil or grease the O-ring.
Otherwise the cup seal (37i) on the joint ring (37c) can turn.

 Coat O-ring with spirit to make installation of the cup seal (37i) easier.

9

Mount cup seal (37i) with clamp (37k) and slide on as far as the end stop on the joint ring (37c).

 Push on the cup seal (37i) carefully.
Otherwise the O-ring will be damaged.

 If necessary, drive fully home by tapping gently with a plastic mallet.

10

Fix cup seal (37i) in circumferential groove of joint ring (37c) by applying four blows around circumference (each blow offset by 90°).

11

By means of even blows with a suitable hammer drive cup seal (37i) into the circumferential groove of the joint ring (37c).

 Ensure that the boot cap (37i) seats properly.

12

By positioning a drift (Ø 4 mm) and applying even blows with the hammer, reposition the cup seal (37i) in the groove.

13

Measure size of joint housing.

 The quantity of grease required depends on the size of the joint housing. Using a vernier caliper, measure the diameter (A) at the outer joint and the diameter (B) at the inner joint. For measuring points, see arrows. For quantity of grease, see Table.

14

Fill joint with new grease. Model 166, 170, 171, 172, 204, 207, 208, 209, 211, 212, 215, 216, 218, 219, 220, 221, 230
Plugged in shaftsModel 217, 222
Plugged in shaftsModel 231Plugged in shafts  MODEL 203 

15

Slide boot (37l) onto cup seal (37i).

 Ensure that the ridge (arrow) on the boot (37l) is resting between the ridges on the boot cap (37i). After the boot is pushed on, no groove on the rear axle shaft should be visible at the small diameter of the boot (37l). This indicates that the raised bead of the boot (37l) is fixed in the first groove.

16

Mount clamps (37k).

 Ensure that dimension (a), measured on the inside, is not exceeded or fallen below.

Dimensions:
a = 2 to 2.5 mm