Remove/install complete rear axle

AR35.10-D-0010I

Remove/install complete rear axle

19.08.2019

Rear axle

741.412 in model 900.63

Rear axle

741.412/415 in model 906.11/13/21/23/61/63/71/73

Rear axle

741.413/414/416/420 in model 906.15/25/65

Rear axle

741.413/414/420 in model 900.65

Rear axle

741.421/423 in model 906.11/13/21/23/61/63/71/73

Rear axle

741.421/455 in model 900

Rear axle

741.422/453/454/455 in model 906.15/25/65

Rear axle

741.428 in model 8AC906.133/631/633/635

with code ZL3 (National version for Latin America)

Rear axle

741.429 in model 8AC906.153/155/655/657

with code ZL3 (National version for Latin America)

Modification notes

16.08.2019

Work procedure revised

The whole document

Shown on model 906.633 with rear axle 741.412 with code PL9 (Air suspension from VB-Airsuspension)

1

Spring U-bolt

2

Spring plate

4

Brake cable

5

Shock absorber

9

Brake caliper

14

Electrical wiring harness

15

Screw

16

Propeller shaft

18

Vent line

19

Nut

21

Seal

22

Torsion bar linkage

35

Spring

S10/3

Left rear brake wear sensor

S10/4

Right rear brake wear sensor

Shown with code LG1 (Bi-xenon headlamps with corner-illuminating fog lamps)

4

Brake cables

20

Linkage rod

30

Nut

31

Cable adjustment device

32

Bracket

33

Jam nut

 Danger

Risk of death from lowering vehicle when working between wheels and body. Risk of injury from pinching or crushing when working on the air suspension.

Testing and repair work between the wheel and wheel arch or in the wheel well should only be performed if the vehicle is secured using suitable support fixtures to prevent it from lowering.
Adjustment operations should only be performed from underneath the vehicle.
Use only suitable support fixtures to secure the vehicle frame or vehicle axles in order to prevent them from lowering.
If necessary, additionally use suitable support fixtures in order to prevent other moving vehicle parts that are in the working area from lowering, or use suitable retaining devices to prevent these parts from moving suddenly and without warning.
Secure areas with moving vehicle parts against unauthorized access.

AS32.22-Z-0001-01A

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Warning

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension

Use only approved tensioning devices; additionally screen off hazardous area if necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves.

AS00.00-Z-0001-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

 

Remove/install

1

Drain compressed air from air suspension.

Model 906 with code PL9 (Air suspension from VB Air suspension)

AR32.22-D-2019H

2

Remove rear wheels.

AR40.10-D-1100H

3

Disconnect electrical connectors from rear left brakepad wear sensor (S10/3) and rear right brakepad wear sensor (S10/4).

4

Remove electrical wiring harnesses (14) from right and left brake caliper (9).

 For this purpose, remove screws (15).

 Bolt, wear indicator to brake caliper

*BA42.10-N-1004-12A

5.1

Remove both brake calipers (9).

If rear axle is reused or if only separate parts are replaced.

AR42.10-D-0080I

 Do not disconnect brake hoses from brake calipers (9). Secure brake calipers (9) at a suitable point outside of working area.

5.2

Remove brake hoses of brake calipers (9).

If rear axle is replaced as a complete part.

AR42.10-D-0013A

 The brake calipers (9) are included in the complete part of a new rear axle.

 Installation: Check brake hoses for wear and damage.

If corresponding findings are present:



Replace affected brake hose.

6

Secure vehicle on vehicle lift.

AR00.60-D-0100H

7.1

Remove linkage (20) of level sensor for headlamp range adjustment from rear axle.

Model 900 with code LG0 (Bi-xenon headlamps) or with code LG1 (Bi-xenon headlamps with corner-illuminating fog lamps), model 906 with code LG0 (Bi-xenon headlamps) except code PL9 (Air suspension from VB-Airsuspension), model 906 with code LG1 (Bi-xenon headlamps with corner-illuminating fog lamps) except code PL9 (Air suspension from VB-Airsuspension)

7.2

Remove linkages (22) of level sensors of air suspension from rear axle.

Model 906 with code PL9 (Air suspension from VB Air suspension)

AR32.33-D-0009H

8

Remove torsion bar linkages from longitudinal member.

 The torsion bar linkages remain on the stabilizer.

 Rear axle 741.412/415 in model 906.13/23/63/73
with code PL9 (Air suspension, company VB-Airsuspension)
Rear axle 741.421/423 in model 906.13/23/63/73
with code PL9 (Air suspension, company VB-Airsuspension)Bolt/nut, torsion bar linkage to longitudinal frame member

*BA32.35-N-1006-03B

 Rear axle 741.412 in model 900.63
Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73
except code PL9 (Air suspension, company VB-Airsuspension)
Rear axle 741.413/414/416/420 in model 906.15/25/65
except code PL9 (Air suspension, company VB-Airsuspension)
Rear axle 741.413/414/416/420 in model 906.15/25/65
with code PL9 (Air suspension, company VB-Airsuspension)
Rear axle 741.413/414/420 in model 900.65
Rear axle 741.421/423 in model 906.11/13/21/23/61/63/71/73
except code PL9 (Air suspension, company VB-Airsuspension)
Rear axle 741.421/455 in model 900
Rear axle 741.422/453/454/455 in model 906.15/25/65
except code PL9 (Air suspension, company VB-Airsuspension)
Rear axle 741.422/453/454/455 in model 906.15/25/65
with code PL9 (Air suspension, company VB-Airsuspension)
Rear axle 741.428 in model 8AC906.133/631/633/635
with code ZL3 (National version for Latin America)
except code PL9 (Air suspension, company VB-Airsuspension)
Rear axle 741.429 in model 8AC906.153/155/655/657
with code PL9 (Air suspension, company VB-Airsuspension)
with code ZL3 (National version for Latin America)
Rear axle 741.429 in model 8AC906.153/155/655/657
with code ZL3 (National version for Latin America)
except code PL9 (Air suspension, company VB-Airsuspension)Screw/bolt, torsion bar linkage to torsion bar/longitudinal frame member

*BA32.35-N-1001-03B

9

Disconnect rear left rpm sensor electrical connector from frame support.

10

Disconnect rear right rpm sensor electrical connector from frame support.

11

Pull bleed line (18) out of frame support at underbody.

 Unhook bleed line (18) from holders on body.

12

Release brake cables (4) from cable adjuster (31).

 To do so, loosen counternut (33) and nut (30).

13

Unhook brake cables (4) from holder (32).

14

Unclip brake cables (4) from frame floor assembly.

 Sleeve

*906589001400

15

Unhook brake cables (4) from holders on frame floor assembly.

16

Remove propeller shaft (16) from rear axle differential.

Remove/install propeller shaft

AR41.10-D-0050H


Secure propeller shaft (16) to body using a suitable wire or rope.
If the propeller shaft (16) hangs freely, the bearings of the universal joints will be damaged.

17

Support rear axle using a mounting plate and a major assembly support.



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

 Secure rear axle against falling down using tensioning strap.

 Commercially available devices/tools
Tensioning strap

18

Fix right and left spring (35) in place on body using tensioning straps.

Model 906 with code PL9 (Air suspension from VB Air suspension)


Fix the right and left spring (35) in place on the body using a tensioning strap so that the right and left spring (35) cannot move in a downward direction.
Otherwise the air bellows will be damaged.

 Commercially available devices/tools
Tensioning strap

19

Remove right and left shock absorber (5) from rear axle.

Remove/install rear shock absorber
Model 900.63/65 except code PL9 (Air suspension from VB-Airsuspension) model 906.1/2/6/7 except code PL9 (Air suspension from VB-Airsuspension)

AR32.25-D-0110H

Remove/install rear shock absorberModel 906.15/25/65 with code PL9 (Air suspension from VB Airsuspension)

AR32.25-D-0110HA

Remove/install rear shock absorberModel 906.11/13/21/23/61/63/71/73 with code PL9 (Air suspension from VB Airsuspension)

AR32.25-D-0110HB

20

Remove right and left spring U-bolt (1).

 To do so, remove nuts (19) from left and right spring U-bolts (1) and take off spring U-bolts (1) with spring plates (2).

 Nut, spring U-bolt for rear axle spring to rear axle

*BA32.20-N-1005-03A

21

Remove right and left shim (21).

Model 906 with code PL9 (Air suspension from VB Air suspension)

 Installation: Pay attention to installation position of plates (21).

22

Remove rear axle.

23

Convert detachable parts.

If rear axle is replaced.


Mark both rpm sensors at rear.
This prevents a mix up.

 The electric line on the right rear rpm sensor is marked at the factory with a white closing strap.

ABS sensor grease

*BR00.45-Z-1019-06A



Check

24

Check rear axle differential for leak tightness.

Notes on evaluating leakages

AH00.00-N-0011-01A

If corresponding findings are present,



perform suitable measures to rectify the leak.

 After obtaining special order.

25

Install in the reverse order.



Check

26

Check position of rear axle relative to body.

Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73
with code PL9 (Air suspension, company VB-Airsuspension)
Rear axle 741.413/414/416/420 in model 906.15/25/65
with code PL9 (Air suspension, company VB-Airsuspension)
Rear axle 741.421/423 in model 906.11/13/21/23/61/63/71/73
with code PL9 (Air suspension, company VB-Airsuspension)
Rear axle 741.422/453/454/455 in model 906.15/25/65
with code PL9 (Air suspension, company VB-Airsuspension)

If corresponding findings are present:



Adjust control arms.

AR35.15-D-0201H

27

Check oil level in rear axle differential.



Rear axle 741.428 in model 8AC906.133/631/633/635
with code ZL3 (National version for Latin America)
Rear axle 741.429 in model 8AC906.153/155/655/657
with code ZL3 (National version for Latin America)

AP35.00-A-3501B



Rear axle 741.412 in model 900.63
Rear axle 741.412/415 in model 906.11/13/21/23/61/63/71/73
Rear axle 741.413/414/416/420 in model 906.15/25/65
Rear axle 741.413/414/420 in model 900.65
Rear axle 741.421/423 in model 906.11/13/21/23/61/63/71/73
Rear axle 741.421/455 in model 900
Rear axle 741.422/453/454/455 in model 906.15/25/65

AP35.00-D-3501A

If corresponding findings are present,



correct oil level.

28

Calibrating driving level.

Model 906 with code PL9 (Air suspension from VB Air suspension)

AR32.22-D-9000H

29

Adjust parking brake.

AR42.20-D-0540H

30

Retighten nuts (19) on right and left spring U-bolts (1).

After a driving distance of 500  to  1000  km.



AP32.20-D-3271H

 Rear-axle steel suspension

Number

Designation

Bolt 900

Model 906.1/2

BA32.20-N-1005-03A

Nut, spring U-bolt for rear axle spring to rear axle

M14x1.5

Stage 1

Nm

160

160

Stage 2

°

-

-

Stage 3

°

-

-

 Rear-axle steel suspension

Number

Designation

Model 906.6/7

BA32.20-N-1005-03A

Nut, spring U-bolt for rear axle spring to rear axle

M14x1.5

Stage 1

Nm

160

Stage 2

°

-

Stage 3

°

-

 Rear axle torsion bar

Number

Designation

Model 900

Model 906.11/131/133/135/21/23/61/63/71/73
except code PL9 (Air suspension, company VB-Airsuspension)

BA32.35-N-1001-03B

Screw/bolt, torsion bar linkage to torsion bar/longitudinal frame member

M121.5

Nm

106

106

M12

Nm

-

-

 Rear axle torsion bar

Number

Designation

Model 906.15/25/65
except code PL9 (Air suspension, company VB-Airsuspension)

Model 906.15/25/65
with code PL9 (Air suspension, company VB-Airsuspension)

BA32.35-N-1001-03B

Screw/bolt, torsion bar linkage to torsion bar/longitudinal frame member

M121.5

Nm

106

-

M12

Nm

-

104

 Rear axle torsion bar

Number

Designation

Model 906.11/131/133/135/21/23/61/63/71/73
with code PL9 (Air suspension, company VB-Airsuspension)

BA32.35-N-1006-03B

Bolt/nut, torsion bar linkage to longitudinal frame member

M12

Nm

80

 Rear axle brake caliper

Number

Designation

Model 900

Model 906

BA42.10-N-1004-12A

Bolt, wear indicator to brake caliper

M6

Nm

8

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1019-06A

ABS sensor grease

A 000 989 62 51 10