Check rear axle differential oil level, correct if necessary

AR35.31-P-0520-03QBS

Check rear axle differential oil level, correct if necessary

MODEL

204.377

with CODE P98 (Black Series)

MODEL

209.377

with CODE P98 (Black Series)

 Rear axle differential housing

Number

Designation

MODEL 204 with CODE P98

BA35.31-P-1005-02H

Threaded insert to rear axle differential housing

Nm

50

 Rear axle differential housing

Number

Designation

MODEL 203.07/27, MODEL 209.372/ 377/472/477, MODEL 209.375/ 376/475/476 as of 24.04.04

BA35.31-P-1006-02B

Threaded chuck to rear axle differential housing

60

 Rear axle differential housing

Number

Designation

MODEL 204 with CODE P98

BA35.31-P-1006-02H

Banjo bolt for oil line to threaded chuck

Stage 1

Nm

5

Stage 2

°

90

 Rear axle differential housing

Number

Designation

MODEL 203.07/27, MODEL 209.372/ 377/472/477, MODEL 209.375/ 376/475/476 as of 24.04.04

BA35.31-P-1007-02B

Banjo bolt for oil line to threaded chuck

Stage 1

Nm

5

Stage 2

°

90

 Differential

Number

Designation

MODEL 209.377/477

BF35.31-P-1001-01K

Filling capacity

Differential

Liter

1,2

Sheet

BB00.40-P-0235-61A

 Rear axle differential

Number

Designation

MODEL 204.377 with CODE P98, except CODEB25

MODEL 204.377 with CODE B25 and CODE P98

BF35.31-P-1001-01T

Filling capacity

Rear axle differential 187 FE, Ø 187 mm

Liter

–

–

Sheet

-

-

Rear axle differential 200 FE, Ø 200 mm

Liter

–

–

Sheet

-

-

Rear axle differential 215 FE, Ø 215 mm

Liter

1,2

1,35

Sheet

BB00.40-P-0235-61A

BB00.40-P-0235-61A

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

Adolf Würth GmbH & Co. KG
Reinhold-Würth-Str. 12-17
74653 Künzelsau-Gaisbach
Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de

BR00.45-Z-1046-04A

Loctite 7063 cleaning spray (150 ml)

A 001 986 71 71 10

BR00.45-Z-1061-01A

Sealant, Omnifit 100H (50 g)

A 002 989 23 71

Shown on model 209.377

1

Differential

2

Cable

4

Connection

1a

Drain screw

2a

Sealing rings

M75

Rear axle differential cooling circuit oil pump

1b

Banjo bolt

3

Threaded insert

1

Clean area around the banjo bolt (1b) and threaded insert (3).

2

Remove banjo bolt (1b) and remove line (2) with seal rings (2a).

 Collect any oil that escapes from the line (2) in an approved container.

3

Seal line (2) with  stop plug and tie upwards.

 The line opening must be located above the filler hole.

4

Unscrew threaded insert (3).

 Do not remove if rear axle differential (1) has to be prefilled.

 Collect escaping oil in approved container.

 Perform operation steps 5 to 14 only after replacing the rear axle differential coolant circuit oil pump (M75), lines, radiator or rear axle differential (1).

5

Prefill differential (1) with the specified oil quantity.

6

Mount line (2) with seal rings (2a) and banjo bolt (1b) on differential (1).

7

Release and disconnect rear axle differential cooling circuit temperature switch connector (X151).

8

Join plug contacts with adapter line  electrical connection kit.

9

Switch on ignition.

 Leave ignition switched on for max. 30 seconds.
The rear axle differential coolant circuit oil pump (M75) can otherwise be damaged.

 Switch on the ignition 2-times in succession for approx. 30 seconds with an interruption in each case of 1 minute.

 The running noise of the rear axle differential coolant circuit oil pump (M75) must become quieter as soon as oil flows through the rear axle differential coolant circuit oil pump (M75). If the rear axle differential coolant circuit oil pump (M75) does not run, determine and eliminate the cause subject to separate repair order.

10

Switch off ignition.

11

Disconnect adapter line and connect rear axle differential cooling circuit temperature switch connector (X15/1) together.

Shown on model 209.377

X15/1

Rear axle differential cooling circuit temperature switch connector

M75

Rear axle differential cooling circuit oil pump

12

Remove banjo bolt (1b) and remove line (2) with seal rings (2a).

 Collect any oil that escapes from the line (2) in an approved container.

13

Seal line (2) with  stop plug and tie upwards.

 The line opening must be located above the filler hole.

14

Unscrew threaded insert (3).

 The threaded insert (3) must be unscrewed from the filler hole.
The rear axle differential (1) will otherwise be overfilled and this could result in leakage, personal injury, damage to property and environmental pollution.

 Collect escaping oil in approved container.

15

Check oil level.

 Allow excess oil to flow out.
An incorrect filling quantity, leakage, personal injury, damage to property and environmental pollution can otherwise occur!

 When the oil level is correct the oil reaches the bottom edge of the oil filler hole in the differential (1).

16

Clean new threaded insert (3) as well as filler hole in differential (1).

 Replace threaded insert (3) whenever it is removed.
Leaks can otherwise occur.

17

Screw new threaded insert (3) into differential (1) and tighten.

 Apply a drop of sealant to the third thread from the bottom and immediately install the new threaded insert (3).

18

Mount line (2) with banjo bolt (1b) on differential (1).

 Install new sealing rings (2a).

19

Carry out leak check on differential (1) and connection points.

 Do not retighten or loosen the connector (4) if there is leakage .
The intake line will otherwise move out of the oil sump and the rear axle differential (1) can overheat. If connector (4) is leaky the end cover must be removed and connector (4) must be resealed.