Disassembling and assembling rear axle differential, adjusting gear set · ar3531p0550c · Mercedes-Benz WIS

AR35.31-P-0550C

Disassembling and assembling rear axle differential, adjusting gear set

2.3.10

Rear axle differential dia. 185
in model 124.003 /004 /007 /019 /022 /023 /026 /027 /030 /040 /042 /043 /050 /060 /062 /079 /082 /083 /090,
124.104 /107 as of 1.5.94,
124.127 /128 /129 /130 /131 /133 /188 /190 /191 /193 /226 /230 /290 /330 /333 /393, 129.060, 170.444 /445 /447 /449, 201.028 /029 /035 /036 /128, 202.020 /022 /023 /024 /025 /026 /028 /029 /080 /081 /082 /083 /086 /087 /088 /089 /128 /188, 208.335 /344 /345 /347 /348 /435 /444 /445 /447 /448, 210.010 /020 /035 /037 /048 /061 /062 /210 /235 /237 /248 /261 /262 /610

Rear axle differential dia. 185
in model 124.020 /021 /080 /081 /120 /125 /126 /180 /185 /186, 201.018 /023 /024 /122 /126 as of 1.11.88,
202.018 /078 /120 /121 /122 /125 /182, 210.003 /004 with CODE (450) taxi version

Rear axle differential dia. 185
in model 124.186 as of 1.3.94,
202.134 /194, 210.007 except CODE (450) Taxi version

Rear axle differential dia. 185 in model 202.018 /120 /121 /125 with CODE (211) rear axle with automatic locking differential (ASD)

Rear axle differential dia. 185 in MODEL 202.085 with TRANSMISSION 722

Disassembling and assembling rear axle differential, adjusting gear set

P35.31-0400-09

11a Tapered roller bearing outer race

11b Tapered roller bearing inner race

13 Differential

13a Retaining bolts

29 Retaining ring

30 Retaining ring

31b Spacer ring

32 Radial sealing ring (standard)

32a Radial sealing ring (ASR)

33 Connecting flange (standard)

33a Connecting flange (ASR)

33b Connecting flange (ASD)

40 Twelve-point collar nut

50 Rear axle center assembly

54 End cover

55 Rear axle breather

56 Screw

56b Collar bolt

70 Ring cylinder

70j Radial sealing ring (ASD)

70l Hydraulic line

71 Oil baffle plate

A Standard version

B ASR version

C ASD version

41 Joint flange

42 Radial sealing ring

43a Thrust washer

43d Tapered roller bearing inner race

43e Tapered roller bearing outer race

44 Spacer sleeve

45 Shim

46a Tapered roller bearing inner race

46b Tapered roller bearing outer race

47 Drive pinion

47a Ring gear

48 Bearing washers

49 ABS gear

	Removing
Danger!	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
1	Raise vehicle with vehicle lift
2	Drain oil from rear axle differential (50)		AR35.31-P-0520-06A
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
		 Oil drain screw	*BA35.31-P-1003-02A
	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04	BT35.31-P-0015-01A
3	Remove rear axle differential (50)	Model 124, 201	ra35001240520x
		Model 129	AR35.31-P-0520C
		Model 170, 202, 208	AR35.31-P-0520D
		Model 210	AR35.31-P-0520B
	Tapped hole for rpm sensor relocated at rear axle housing	Model 124, 129, 201	BT35.31-P-0004-01A
	Features, installation survey for rear axle differentials	Model 124, 129, 170, 201, 202, 208, 210 up to 30.6.99	GF35.31-P-1000-01C
	Disassemble
4	Clamp rear axle differential (50)  in assembly stand.		AR35.31-P-0540-06B
5	Remove end cover (54)
	Rear axle differential end cover with non-machined sealing surface	Model 170, 208, 210 as of 08.05.00, 202.087 /088 /089 /188, 202.078 with CODE (450) Taxi version, 202.194 except CODE (450) Taxi version	BT35.31-P-0014-01A
6.1	Pull retaining rings (30) off both connecting flanges (33 or 33a, 33b).		AR35.31-P-0540-01A
7.1	Pull out connecting flanges (33 or 33a, 33b).	
	Radial seal on side of rear axle housing and connecting flange modified	As of 01.04.98, vehicles without ASD/ASR	BT35.31-P-0013-01A
8	Press off left and right radial sealing rings (32, 32a, 70j).	 Vehicles with code (211) Rear axle with automatic locking differential (ASD)	AR35.31-P-0540-05G
		Vehicles with code (471) Acceleration skid control (ASR)	AR35.31-P-0540-05H
		Vehicles without ASD/ASR	AR35.31-P-0540-05F
	Radial seal on side of rear axle housing and connecting flange modified	As of 01.04.98, vehicles without ASD/ASR	BT35.31-P-0013-01A
9.1	Remove hydraulic line (70l).	Vehicles with code (211) Rear axle with automatic locking differential (ASD)	AR35.41-P-0545-01C
	Routing of hydraulic line and ASD ring cylinder modified	As of 07/89	BT35.41-P-0002-01A
10.1	Remove ring cylinder (70).	Vehicles with code (211) Automatic locking differential (ASD)	AR35.41-P-0545-02C
11.1	Remove oil baffle plate (71).	Vehicles with code (211) Automatic locking differential (ASD)
12	Remove right retaining ring (29) from rear axle housing using spreader.	  Mark retaining ring (29).	AR35.31-P-0550-36C
13	Remove left retaining ring (29) from rear axle housing using spreader.	 Mark the retaining ring (29).
14	Remove both tapered roller bearing outer races (11a) out of rear axle housing	  Mark tapered roller bearing outer races (11a)	AR35.31-P-0550-02C
15	Take differential (13) out of rear axle housing		AR35.31-P-0550-03B
16	Detach both tapered roller bearing inner races (11b) from differential (13)	  Mark tapered roller bearing inner races (11b).	AR35.31-P-0550-04C
17	Loosen and remove retaining bolts (13a) from crown wheel (47a)	 Mark position of ring gear (47a) in relation to differential (13).
18	Carefully press off crown wheel (47a) from differential (13)
19	Loosen and remove twelve-point collar nut (40) from joint flange (41).		AR35.31-P-0550-35C
20	Detach joint flange (41).	  If necessary, mark joint flange with respect to drive pinion.	AR35.31-P-0550-06B
	Radial sealing ring and joint flange on drive pinion modified	As of 01.04.98	BT35.31-P-0012-01A
	Radial sealing ring and joint flange on drive pinion modified	As of 15.01.02	BT35.31-P-0012-01B
21	Push drive pinion (47) out of rear axle housing		AR35.31-P-0550-07A
22	Press radial sealing ring (42) out of the rear axle housing using a suitable screwdriver.		AR35.31-P-0550-08B
	Radial sealing ring and joint flange on drive pinion modified	As of 01.04.98	BT35.31-P-0012-01A
	Radial sealing ring and joint flange on drive pinion modified	As of 15.01.02	BT35.31-P-0012-01B
23	Remove tapered roller bearing inner race (43d) with thrust washer (43a).
	Integrated thrust washer on tapered roller bearing inner race	Model 124, 129, 201 as of 03/94	BT35.31-P-9402-01A
24	Remove tapered roller bearing outer races (46b, 43e) and shim (45) from rear axle housing.		AR35.31-P-0550-09C
25	Remove spacer sleeve (44) with thrust plates (48) from drive pinion (47)
26.1	Pull ABS gear (49) off drive pinion (47).	Vehicles with code (470) Antilock brake system (ABS) , except vehicles with ETS, ASR, ESP and except model 170	AR35.31-P-0550-30B
27	Pull tapered roller bearing inner race (46a) from drive pinion (47)		AR35.31-P-0550-10C
	Checking
28	Inspect all parts to determine whether they can be reused, replace if necessary	 If the contact surfaces of the connecting and joint flanges show signs of severe galling due to the radial sealing ring, the flanges must be replaced with new flanges.
29.1	Check drive pinion (47) and ring gear (47a) for match-up number	Only lapped gear sets up to approx. 06/95 have a match-up number.	AR35.31-P-0550-11A
		 Each lapped gear set is checked for the best possible smooth running and marked with a consecutive match-up number that is marked on both parts.
	Ground ring gear and pinions	Phased in as of 06/95	BT35.31-P-0011-01B
	Ground ring gear and pinions	Model 201.028/029 	BT35.31-P-0011-01A
	Assembly, adjusting ring gear and pinion
30	Press tapered roller bearing inner race (46a) onto drive pinion (47)		AR35.31-P-0550-12C
	Press-on sleeve for tapered roller bearing inner race		WF58.50-P-3531-03B
31.1	Press ABS gear (49) onto drive pinion (47).	Vehicles with code (470) Antilock brake system (ABS) , except vehicles with ETS, ASR, ESP and except model 170	AR35.31-P-0550-31B
	Press-on sleeve for ABS gear		WF58.50-P-3531-04B
		Number of teeth on ABS gear: 
		Features, installation survey for rear axle differentials	GF35.31-P-1000-01C
32	Calculate shim (45) and installing in rear axle housing	  Use data sheet: 	AR35.31-P-0550-13C
		Data sheet, Adjusting rear axle gear set: Order No. B20.800.98.113.00C
33	Pull tapered roller bearing outer races (43e, 46b) into rear axle housing		AR35.31-P-0550-14C
34	Install spacer sleeve (44) on drive pinion (47) with double-sided thrust plates (48)	 Always replace spacer sleeve (44) and thrust plates (48).	AR35.31-P-0550-26B
35	Insert drive pinion (47) into rear axle housing.	  Support drive pinion (47) with removal and installation tool.	AR35.31-P-0550-15B
36.1	Clip pressure plate (43a) onto tapered roller bearing inner race (43d).	Rear axle differentials up to 02/94	AR35.31-P-0550-37C
	Integrated thrust washer on tapered roller bearing inner race		BT35.31-P-9402-01A
37	Install tapered roller bearing inner race (43d) on drive pinion (47) and press in together with radial sealing ring (42).	  Replace radial sealing ring (42) and coat the lip with universal hypoid gear oil.	AR35.31-P-0550-16C
	Universal hypoid gear oils		BB00.40-P-0235-07A
	Radial sealing ring and joint flange on drive pinion modified	As of 01.04.98	BT35.31-P-0012-01A
	Radial sealing ring and joint flange on drive pinion modified	As of 15.01.02	BT35.31-P-0012-01B
38	Slide joint flange (41) onto drive pinion (47)	 Possibly observe applied marking. Coat contact face for radial sealing ring with universal hypoid gear oil.
	Universal hypoid gear oils		BB00.40-P-0235-07A
	Radial sealing ring and joint flange on drive pinion modified	As of 01.04.98	BT35.31-P-0012-01A
	Radial sealing ring and joint flange on drive pinion modified	As of 15.01.02	BT35.31-P-0012-01B
	Imbalance on drive pinion joint flange reduced	Model 124, 129, 201	BT35.31-P-0007-01A
39	Screw on twelve-point collar nut (40).	 Install new twelve-point collar nut (40).
		 Socket	*126589020900
40	Adjusting friction torque of drive pinion bearing		AR35.31-P-0550-17C
41	Check adjustment dimension for drive pinion (47)		AR35.31-P-0550-18C
42	Secure twelve-point collar nut (40) on joint flange (41).		AR35.31-P-0530-01B
	Chisel for securing collar nut on joint flange		WF58.50-P-3531-01A
43.1	Dismantling and assembling differential (13)	Vehicles with ASD except	AR35.31-P-0560A
43.2	Disassemble/assemble ASD differential (13).	Vehicles with code (211) Rear axle with automatic locking differential (ASD) up to 31.5.94	AR35.41-P-0560C
44	Mount ring gear (47a) onto differential (13)	  Observe marking applied to ring gear (47a) and differential (13).	AR35.31-P-0550-19A
	Tightening torque of ring gear bolts reduced	Model 124, 129, 201 as of 01.02.87	BT35.31-P-0005-01A
45	Press tapered roller bearing inner races (11b) onto differential (13)		AR35.31-P-0550-20C
46	Install differential (13) in rear axle housing	 Fix differential (13) with drifts.	AR35.31-P-0550-03B
47	Insert left tapered roller bearing outer race (11a) into rear axle housing		AR35.31-P-0550-38C
48	Insert left retaining ring (29)	 Install the retaining ring (29) removed and marked previously in order to achieve a basic pre-tension of the rear axle housing.	AR35.31-P-0550-27C
49	 Remove right drift from differential (13).
50	Install right tapered roller bearing outer race (11a) in rear axle housing.	 Drift	*126589001500
51	Pretension (spread) rear axle housing using  spreader.	  Ensure that the dial indicator with measuring bracket remains in position "0".	AR35.31-P-0550-23C
52	Insert right retaining ring (29)	 Install the retaining ring (29) removed and marked previously in order to achieve a basic pre-tension of the rear axle housing.	AR35.31-P-0550-22C
53	Release rear axle housing
54	Measure expanded dimension of rear axle housing		AR35.31-P-0550-24C
55	 Remove spreader from rear axle housing
56	Measure gear backlash between drive pinion (47) and ring gear (47a), correct if necessary.	  The adjustment of the tapered roller bearing and the gear set is OK when the spread dimension (expansion) of the rear axle housing and the gear backlash are within the nominal values. This prevents damage to the teeth of the drive pinion gear (47) and the ring gear (47a).	AR35.31-P-0550-25C
57	Check that retaining ring (29) is correctly seated.		AR35.31-P-0550-32C
58	Install oil baffle plate (71).	Vehicles with code (211) Rear axle with automatic locking differential (ASD)	AR35.41-P-0545-03C
		 Ensure correct seating.
59	Attach ring cylinder (70).	Vehicles with code (211) Rear axle with automatic locking differential (ASD)	AR35.41-P-0545-02C
		 Coat ring cylinder at circumference of O-ring with hydraulic fluid.
	Hydraulic fluids (Specification 343.0)		BB00.40-P-0343-00A
60	Attach hydraulic line (70l).	Vehicles with code (211) Rear axle with automatic locking differential (ASD)	AR35.41-P-0545-01C
	Routing of hydraulic line and ASD ring cylinder modified		BT35.41-P-0002-01A
61	Press radial sealing rings (32 or 32a, 70j) into rear axle housing.	  Install new radial sealing ring and coat lip with universal hypoid gear oil.
	Universal hypoid gear oils		BB00.40-P-0235-07A
		Vehicles with code (211) Rear axle with automatic locking differential (ASD)	AR35.31-P-0540-05G
		Vehicles with code (471) Acceleration skid control (ASR)	AR35.31-P-0540-05H
		Vehicles without ASD/ASR	AR35.31-P-0540-05F
	Radial seal on side of rear axle housing and connecting flange modified	As of 01.04.98, vehicles without ASD/ASR	BT35.31-P-0013-01A
62.1	Slide spacer rings (31b) onto connecting flanges (33 or 33a).	Vehicles without ASD
63.1	Install connecting flanges (33 or 33a, 33b) in differential (13).
	Connecting flange with centering	Model 124, 129, 201	BT35.31-P-0009-01A
	Radial seal on side of rear axle housing and connecting flange modified	As of 01.04.98, vehicles without ASD/ASR	BT35.31-P-0013-01A
64.1	Fit retaining rings (30) onto connecting flanges.		AR35.31-P-0540-01A
		 Install new retaining ring (30).
65.1	Check and adjust axial play of connecting flange	Vehicles without ASD	AR35.31-P-0540-02E
		 On vehicles with code (211) Rear axle with automatic locking differential (ASD) no axial play adjustment is required.
66	Attach end cover (54)	 If a replacement part end cover is mounted, it is essential to observe whether the sealing surface is machined or unmachined. Use suitable sealant.
		End cover with machined sealing surface in model 124, 129, 201 and in model 170, 202, 208, 210 up to 07.05.00	AR35.31-P-0550-28C
		End cover with unmachined sealing surface in model 170, 202, 208, 210 as of 08.05.00	AR35.31-P-0550-28CA
	End cover with unmachined sealing surface	Vehicles as of 08.05.00	BT35.31-P-0014-01A
67	Replace rear axle breather (55) on end cover (54)	 Model 124, 129, 170, 201, 202, 208, 210	*BA35.31-P-1005-02A
68	Remove rear axle differential (50) from  assembly stand
	Install
69	Install rear axle differential (50).	Model 124, 201	ra35001240520x
		Model 129	AR35.31-P-0520C
		Model 170, 202, 208	AR35.31-P-0520D
		Model 210	AR35.31-P-0520B
70	Pour oil into the rear axle differential (50)	Model 129, 170, 202, 208, 210	AR35.31-P-0520-03A
		 Model 129	*BF35.31-P-1001-01C
		 Model170	*BF35.31-P-1001-01F
		 Model 202	*BF35.31-P-1001-01D
		 Model 208	*BF35.31-P-1001-01H
		 Model 210	*BF35.31-P-1001-01E
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
		 Oil filler screw for rear axle differential	*BA35.31-P-1002-02A
		Model 124, 201	AR35.31-P-0520-03AA
		 Model124	*BF35.31-P-1001-01B
		 Model 201	*BF35.31-P-1001-01G
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
		 Oil filler screw for rear axle differential	*BA35.31-P-1002-02A
	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04	BT35.31-P-0015-01A
71.1	Bleed ASD hydraulic system	Vehicles with code (211) Rear axle with automatic locking differential (ASD) :
		Model 124, 201	ra35001240519x
		Model 129, 202	AR35.41-P-0519C

Test values for friction torque of rear axle differential

Number	Designation		Model 124.003/004/007/ 019/022/023/026/027/ 030/040/042/043/050/ 060/062/079/082/083/ 090 Model 124.104/107 as of 01.05.94 Model 124.127/128/129/ 130/131/133 Model 124.186 as of 01.03.94, except (code 450) taxi version Model 124.188/190/191/ 193/226/230/290/330/ 333/393	Model 124.020/021/080/ 081/120/125/126/180/ 185/186, with (code 450) taxi version as of 01.11.88	Model 129.060


BE35.31-P-1001-02C	Friction torque of drive pinion bearing (new tapered roller bearings)	Ncm	125-150	125-150	125-150

Test values for friction torque of rear axle differential

Number	Designation		Model 170.444/445/ 447/449	Model 201.018/023/024/ 122/126, with (code 450) taxi version as of 01.11.88	Model 201.028/ 029/035/ 036/128


BE35.31-P-1001-02C	Friction torque of drive pinion bearing (new tapered roller bearings)	Ncm	125-150	125-150	125-150

Test values for friction torque of rear axle differential

Number	Designation		Model 202.018/078/120/ 121/122/125/182 with (code 450) taxi version, Model 202.018/020/022/ 120/121/125 with ASD (code 211)	Model 202.020/022/023/ 024/025/026/028/029/ 080/081/082/083/086/ 087/088/089/128/188 Model 202.085 with automatic 5-speed transmission, model 202.134/194, except (code 450)


BE35.31-P-1001-02C	Friction torque of drive pinion bearing (new tapered roller bearings)	Ncm	125-150	125-150

Test values for friction torque of rear axle differential

Number	Designation		Model 208.335/344/345/ 347/348/435/ 444/445/447/448	Model 210.010/ 020/035/037/ 048/061/062/ 210/235/237/ 248/261/262/610


BE35.31-P-1001-02C	Friction torque of drive pinion bearing (new tapered roller bearings)	Ncm	125-150	125-150

Test values for friction torque of rear axle differential

Number	Designation		Model 210.003/004 with (Code 450) 210.007 except code 450


BE35.31-P-1001-02C	Friction torque of drive pinion bearing (new tapered roller bearings)	Ncm	125-150

Test values for rear axle differential

Number	Designation		Model 124	Model 129	Model 170


BE35.31-P-1001-03A	Permissible deviation from the specified adjustment dimension on the end face of the drive pinion	mm	-0.02/+0.01	-0.02/+0.01	-0.02/+0.01
BE35.31-P-1002-03A	Gear backlash between crown wheel and pinion	mm	0,08-0,14	0,08-0,14	0,08-0,14
BE35.31-P-1003-03A	Crown wheel heating temperature for installation	°C	75-85	75-85	75-85

Test values for rear axle differential

Number	Designation		Model 201	Model 202


BE35.31-P-1001-03A	Permissible deviation from the specified adjustment dimension on the end face of the drive pinion	mm	-0.02/+0.01	-0.02/+0.01
BE35.31-P-1002-03A	Gear backlash between crown wheel and pinion	mm	0,08-0,14	0,08-0,14
BE35.31-P-1003-03A	Crown wheel heating temperature for installation	°C	75-85	75-85

Test values for rear axle differential

Number	Designation		Model 208	Model 210


BE35.31-P-1001-03A	Permissible deviation from the specified adjustment dimension on the end face of the drive pinion	mm	-0.02/+0.01	-0.02/+0.01
BE35.31-P-1002-03A	Gear backlash between crown wheel and pinion	mm	0,08-0,14	0,08-0,14
BE35.31-P-1003-03A	Crown wheel heating temperature for installation	°C	75-85	75-85