Remove/install complete rear axle

AR35.10-D-0010R

Remove/install complete rear axle

10.02.2017

Rear axle

741.408 in model 909

Shown on model 909.632

1

Spring U-bolt

19

Electrical line

31

Bracket

2

Plate

20

Bolt

33

Bracket

4

Brake cable

24

Nut

L6/3

Left rear rpm sensor

5

Shock absorber

25

Propeller shaft

L6/4

Right rear rpm sensor

15

Brake caliper

27

Vent line

18

Brake wear sensor

28

Nut

4

Brake cables

34

Fastening bracket

 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

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on repair work on suspension components

AH00.00-P-0100-01A



Remove

1

Secure vehicle on vehicle lift

AR00.60-D-0100F

2

Remove complete wheels at rear

AR40.10-D-1100F

3

Release and disconnect brakepad wear sensor (18) from electric line (19) on right and left brake caliper (15)

4

Remove screws/bolts (20) and detach electrical line (19) from right and left brake caliper (15)

5

Mark left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4)

6

Remove rear left rpm sensor (L6/3) and rear right rpm sensor (L6/4)

7

Remove cable ties (arrows) from brake cables (4) and rear axle

8

Expose electrical lines (19) up to mounting console (34)

9

Expose electrical line for left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4) up to mounting console (34)

10

Detach brake cables (4)

AR42.20-D-0520-03F

11

Unclip retaining rings from mounting console (34) and remove brake cables (4)

 Clip remover

*901589006300

12

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

Rear axle 741.408 in model 909.63

AR32.25-D-0110FA

13

Check shock absorbers (5)

AR32.25-D-0121A

If there are problems



Replace right or left shock absorber (5).

Rear axle 741.408 in model 909.63

AR32.25-D-0110FA

14

Pull vent line (27) out of frame

15

Remove propeller shaft (25) from rear axle flange and fix in place on vehicle

AR41.10-D-0050R


Do not let drive shaft (25) hang down.
Otherwise the needle roller bearing in the universal joint will be damaged.

16

Remove right and left brake caliper (15) and fix in to place on vehicle

Rear axle 741.408 in model 909.63

AR42.10-D-0080FD

17

Support rear axle using mounting plate and major assembly mount



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

18

Secure rear axle using tensioning strap against falling down

19

Unscrew nuts (28) on right and left spring U-bolts (1) and remove spring U-bolts (1) and plates (2)

20

Lower rear axle carefully

21

Remove holders (31, 33) for brake cables (4) from rear axle tube

When replacing rear axle.

22

Heat up bleed line (27) and remove

When replacing rear axle.



000 588 00 84 00 Heat gun

WS54.00-P-0049B



Install

23

Heat up and mount bleed line (27)

When replacing rear axle.



000 588 00 84 00 Heat gun

WS54.00-P-0049B

24

Mount holders (31, 33) for brake cables (4) onto rear axle tube

When replacing rear axle.

25

Carefully lift up rear axle using major-assembly mounting



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

26

Attach spring U-bolts (1) and plates (2) and tighten nuts (28) on right and left spring U-bolts (1)

 Replace nuts (28).

 Spring U-bolt on rear axle spring to rear axle

*BA32.20-N-1005-03A

27

Release rear axle from mounting plate and major assembly mount and remove mounting plate and major assembly mount



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

28

Install right and left brake caliper (15)

Rear axle 741.408 in model 909.63

AR42.10-D-0080FD

29

Mount propeller shaft (25) onto rear axle flange

AR41.10-D-0050R

30

Route vent line (27) in the frame

31

Install right and left shock absorber (5) onto rear axle

Rear axle 741.408 in model 909.63

AR32.25-D-0110FA

 Replace nuts (24).

32

Install brake cables (4) and clip in retaining rings at mounting bracket (34)

33

Hook in brake cables (4)

34

Route electrical line of left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4)

 Replace cable ties.

35

Route electrical lines (19)

 Replace cable ties.

36

Attach cable ties (arrows) onto brake cables (4) and rear axle

 Replace cable ties.

 Pliers

*352589023700

37

Coat left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4) with grease

ABS sensor grease

*BR00.45-Z-1019-06A

38

Install rear left rpm sensor (L6/3) and rear right rpm sensor (L6/4)

 Observe marks for restoring installation position.

 Screw/bolt, ABS sensor to rear axle

*BA42.30-N-1002-02B

39

Attach electrical lines (19) to right and left brake caliper (15) and tighten screws/bolts (20)

 Bolt, wear indicator to brake caliper

*BA42.10-N-1004-12A

40

Connect brakepad wear display sensor (18) with electric line (19) on right and left brake caliper

41

Remove rear wheel and tire assembly

AR40.10-D-1100F

42

Disconnect vehicle from vehicle lift

AR00.60-D-0100F



Check

 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

43

Check oil level in rear axle differential

 If necessary, add oil up to lower edge of oil filler opening.

 Oil filler plug

*BA35.10-N-1002-03A

 Hypoid transmission oil

*BF35.10-N-1001-01A

44

Adjust parking brake

Rear axle 741.408 in model 909.63

AR42.20-D-0540FA

45

Tighten nuts (28) on spring U-bolts (1)

After a driving distance of 500 km to 1000 km.



AP32.20-D-3271R

 Rear-axle steel suspension

Number

Designation

Model 909.63

BA32.20-N-1005-03A

Spring U-bolt on rear axle spring to rear axle

M141.5

Nm

170

 Rear axle

Number

Designation

Rear axle 741.130/131/407/408/409

BA35.10-N-1002-03A

Oil filler plug

Nm

100

 Rear axle brake caliper

Number

Designation

Model 909.63

BA42.10-N-1004-12A

Bolt, wear indicator to brake caliper

M6

Nm

10

 Rear axle rpm sensor

Number

Designation

Model 909

BA42.30-N-1002-02B

Screw/bolt, ABS sensor to rear axle

Nm

8

 Rear axle

Number

Designation

Rear axle 741.408/409

BF35.10-N-1001-01A

Hypoid transmission oil

Filling capacity

Liter

1,8

Sheet

BB00.40-P-0235-00A

Sheet

BB00.40-P-0235-06A

Sheet

BB00.40-P-0235-08A

Repair materials

Number

Designation

Order number

BR00.45-Z-1019-06A

ABS sensor grease

A 000 989 62 51 10