Constant-velocity joint or rubber boot on rear halfshaft - removal and installation

AR35.30-P-0661P

Constant-velocity joint or rubber boot on rear halfshaft - removal and installation

30.7.15

Model

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

37a

Rear axle shaft

37e

Ball

37l

Rubber boot

37b

Outside joint ring

37f

Ball retainer

37m

Rubber boot

37c

Inner joint ring

37i

Cup seal

37n

O-ring

37d

Joint hub

37k

Clamps

37o

Cap

 

Remove/install

1

Clamp rear axle shaft (37a) in vise

 Use soft vise jaws.
Check availability of a repair kit for the rubber boot in the EPC (repair possible on certain rear axle shafts (37a) only).

2

Remove clamps (37k)

 Installation: Replace clamps (37k), note clamp width while doing so.

3

Remove cup seal (37i) from inner joint ring (37c) and outer joint ring (37b)

AR35.30-P-0661-01P

 Installation: Do not oil or grease O-ring (37n).

 Model 166, 170, 171, 172, 204, 207, 208, 209, 211, 212, 215, 216, 218, 219, 220, 221, 230, 292
Plugged in shafts
Model 231
Plugged in shaftsFilling capacity for joint housing

*BF35.30-P-1001-01G

 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)Filling capacity for joint housing

*BF35.30-P-1003-01D

4

Dismantle constant-velocity joint

AR35.30-P-0661-03P

5

Press joint hub (37d) off the rear axle shaft (37a)

AR35.30-P-0661-02P



Shell halves (2 ea.) for pressing off and caulking the inner constant velocity joint.

WF58.50-P-3530-01A



Staking tool for securing joint hub on rear halfshaft

WF58.50-P-3530-07P

 Drift

*116589151500

6

Remove rubber boot (37l) from opposite constant velocity joint

Only if necessary.

 The rubber boot (37l) can be removed by way of the rear axle shaft (37a).



Check

7

Check constant velocity joints for wear

AR35.30-P-0661-03P

 If the outer constant velocity joint is defective, then the rear axle shaft (37a) must be replaced.

8

Install in the reverse order

 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 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

 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-1003-01D

Filling capacity for joint housing

Rear axle shaft (inserted)

Ø95

g

100

–

Ø102

g

120

–

Ø106

g

130

–

Ø112

g

140

–

Ø116

g

150

–

 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-1003-01D

Filling capacity for joint housing

Rear axle shaft (inserted)

Ø95

g

–

–

Ø102

g

–

–

Ø106

g

–

–

Ø112

g

–

–

Ø116

g

–

–

 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-1003-01D

Filling capacity for joint housing

Rear axle shaft (inserted)

Ø95

g

–

–

Ø102

g

–

–

Ø106

g

–

–

Ø112

g

–

–

Ø116

g

–

–

 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-1003-01D

Filling capacity for joint housing

Rear axle shaft (inserted)

Ø95

g

–

–

Ø102

g

–

–

Ø106

g

–

–

Ø112

g

–

–

Ø116

g

–

–

 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-1003-01D

Filling capacity for joint housing

Rear axle shaft (inserted)

Ø95

g

–

–

Ø102

g

–

–

Ø106

g

–

–

Ø112

g

–

–

Ø116

g

–

–