Remove/install complete rear axle

AR35.10-D-0010B

Remove/install complete rear axle

17.10.11

4.2.03

Repair method modified. Hydraulic lines remain connected. Brake calipers and differential lock shift cylinder remain in vehicle.

 

Remove/install



Notes on installing a modified final drive ratio

Model 901.6, 902.6, 903.6, 904.6, 905.6

AH35.00-N-0001-01A

1

Remove rear wheels

AR40.10-D-1100A

2

Unplug cable of brake pad wear indicator (18)

3

Detach connection cable for brake pad wear indicator (19)

 Installation:Install new bolt (20).



*BA42.10-N-1004-12A

4.1

Pull ABS sensor (11) with plug bushing of ABS sensor (12) out of the mounting hole

With code BB0, ABS.

 To prevent confusion, label ABS sensors before disconnecting.

 The cable of the ABS sensor on the right-hand side is labeled at the factory with a white tag.

 Installation: Install new clamping bush (12).

AR42.30-D-0620-01A

Acid-free grease

*BR00.45-Z-1019-06A

5

Remove cable ties from hand brake cable (4) and uncover connecting cable for brake pad wear indicator (19) and if necessary for ABS sensor up to relay unit of parking brake



*352589023700

6

Disconnect brake cables

AR42.20-D-0520-03A

 Installation: Adjust parking brake.

AR42.20-D-0540A

7

Remove hand brake cable (4) at the relay unit

 Compress circlip on the transfer unit.



*901589006300

8.1

Detach bracket for brake cables at rear axle tube (31) and at bracket for stabilizer bar fastening (33)

When installing new rear axle except code C42/C43, stabilizer bar.

 Installation: Transfer brackets (31, 33).

8.2

Detach bracket for brake cables at rear axle tube (31).

When installing new rear axle with code C42/C43, stabilizer bar.

 Installation: Transfer bracket.

9.1

Detach stabilizer bar (31) at rear axle

With code C42/C43, stabilizer bar.

 Installation: Install new nut (30).

AR32.35-D-2210A

10

Unscrew both shock absorbers (5) at rear axle

 Installation: Install new nuts (24 or 22 (with all-wheel)).



*BA32.25-N-1001-03A

11

Detach ALB lever (6) from rear axle bracket

 Installation: Install new nut (7).



*BA42.80-N-1001-01A

12.1

Detach shift cylinder of differential lock (10) and tie back.

With code A71, differential lock.

 Do not twist, kink or pull brake hoses.

 Leave hydraulic line connected.

 Installation: Install new seal (8).

 When reinstalling axle that has been removed, mark position of shift cylinder in relation to axle and reinstall in this position.



*BA35.40-N-1002-01B

 Adjust shift cylinder when installing new axle:

Install and adjust differential lock shift cylinder

AR35.40-D-9131-02A



*BA35.40-N-1002-01B

13

Pull vent line (27) out of frame

 Transfer vent line when installing new axle.

14

Unscrew propeller shaft (25) at rear axle flange and tie to the side.

 Do not allow propeller shaft to dangle down otherwise the needle roller bearings in the universal joint could be damaged.



*BA41.10-N-1002-01B



*000589210100



*001589442100



Notes on installing propeller shaft

Models 690.6, 901, 902, 903, 904

AH41.10-N-0001-01A

15

Unscrew both brake calipers (15) and tie to the vehicle with wire.

 Do not twist, kink or pull brake hoses (13).

 Installation: Replace bolts (14).



*BA42.10-N-1001-12A

16

Move telescopic jack under axle, support axle and secure axle against falling down using tensioning strap on jack

Telescopic lifter
gotis://H_00.10_01.0

17

Unscrew nuts (28) on spring brackets (1), remove spring brackets (1) and spring plates (2)

 Installation: Replace nut (28).



*BA32.20-N-1005-03A

18

Remove rear axle.

 Installation: Transfer spring pad (3) (for all-wheel).

19

Install in the reverse order

20

Inspect oil level at rear axle without changing oil, adjust to correct level if necessary



AP35.00-D-3501A

Number

Designation

Model 690.611/
630/631/
640/641, 901, 902,
903

BA32.20-N-1005-03A

Rear spring U-bolt to rear axle

M141.5

Nm

170

Number

Designation

Models 690.6, 901, 902, 903
with rear axle 741.40

BA32.25-N-1001-03A

Nut/bolt, shock absorber to rear axle

M121.5

8.8

Nm

70

M121.5

10.9

Nm

110

M141.5

Nm

-

Number

Designation

Rear axle
741.407/408/130/
131 with differential lock (code A71)

BA35.40-N-1002-01B

Bolt, shift cylinder to rear axle beam

M8

Nm

25

Number

Designation

Model
690.6, 901, 902, 903, 904, 905 except Minibus Sprinter Low Floor

BA41.10-N-1002-01B

Bolt, rear propeller shaft to rear axle

M101

Stage 1

Nm

70

Stage 2

°

-

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

Number

Designation

Model
690.6

Model
901, 902

Model
903

BA42.10-N-1001-12A

Bolt, brake caliper support to rear axle tube

M121.5

Nm

105

105

105

M141.5

Stage 1

Nm

170

-

-

Stage 2

°

-

-

-

M161.5

Stage 1

Nm

-

-

-

Stage 2

°

-

-

-

BA42.10-N-1004-12A

Bolt, wear indicator to brake caliper

M6

Nm

10

10

10

Number

Designation

Model
690.6, 901, 902, 903, 904, 905

BA42.80-N-1001-01A

Nut, actuator rod to ALB lever and rear axle

M10

Nm

34

Number

Designation

Order number

BR00.45-Z-1019-06A

ABS sensor grease

A 000 989 62 51 10