Remove/install complete rear axle

AR35.10-P-0010D

Remove/install complete rear axle

12.9.11

20.3.04

Oil filler/drain screw on rear axle differential modified

Phased in as of 19.01.04

 The oil filler screws and oil drain screws should always be replaced after being unscrewed.

The new oil filler screws and drain screws as well as the tapped holes must be cleaned with a special cleaning spray and provided with a special sealing compound.

BT35.31-P-0015-01A

The oil filler screw should always be replaced after being unscrewed from the rear axle differential.

The new oil filler screw as well as the tapped hole must be cleaned with a special cleaning spray and the oil filler screw provided with a special sealing compound

 Only carry out oil level check at interior temperature.

AR35.31-P-0520-03A

20.3.04

The vehicle must have a chassis alignment check after the rear axle is installed

Fig. item etc.

Work instructions

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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 Installation

Bleed ASD hydraulic system

Model Series 202 with ASD up to 05/94

AR35.41-P-0519C

 Installation

Check vehicle level at rear axle

AR40.20-P-0300A

 Installation

Check oil level in rear axle differential and correct if necessary

 Mixing of old universal hypoid gear oil and the new FE hypoid gear oil should be avoided due to the better fuel economy.

AR35.31-P-0520-03A

 Model 170

*BF35.31-P-1001-01F

 Model 202

*BF35.31-P-1001-01D

 Model 208

*BF35.31-P-1001-01H

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

Sealant, Omnifit 100H (50 g)

*BR00.45-Z-1061-01A

 Oil filler plug

*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

 Installation

Perform wheel alignment check

AR40.20-P-0200A

 Installation

Check headlamp adjustment and correct if necessary



Check and correct headlamp adjustment

AP82.10-P-8260A



Assembly attachment

*140589016200



Guard plate

*220589013100

1c

Front rear rear-axle suspension bolt

 Installation: Recut thread on frame floor with tap.



*BA35.10-P-1001-01A

1d

Rear rear-axle suspension bolt

 Installation: Recut thread on frame floor with tap.



*BA35.10-P-1002-01A

6g

Spring control arm covering

6i

Remove/install rear spring

Remove both rear springs.

AR32.20-P-0230A

 Danger!

Risk of injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

6j

Detach dampers or suspension struts from the spring control arms

 Vehicles without ride-height control.

*BA32.25-P-1003-03A

 Vehicles with ride-height control.

*BA32.30-P-1003-01B

6k

Stabilizer bar link rod



*BA32.20-P-1002-04C

36

Detach both frame cross struts

 Model 170 only

*BA61.10-P-1001-01A

 Model 208.4 only

*BA61.10-P-1003-01C

105

Remove / install exhaust system from flange connection

Refer to: Remove/install exhaust system complete: 

Model 170 with engines 111.943/946/973

AR49.10-P-7000G

Model Series 170 with Engine 111.958/983

AR49.10-P-7000GS

Model 170 with engine 112

AR49.10-P-7000SV

Model 202 with engine 104, 111

AR49.10-P-7000D

Model 202 with engine 601

ra49006010100x

Model 202 with engine 604, 605

AR49.10-P-7000I

Model 202 with engine 611

AR49.10-P-7000HB

Model 202, 208 with engine 112, 113

AR49.10-P-7000AU

Model 208 with engine 111

AR49.10-P-7000DA

105c

Exhaust shielding plate

106

Remove rear of driveshaft at joint flange

 Flex disk remains on propeller shaft.

Loosen fitting sleeves on flexible couplings.

AR41.10-P-0050-09DA



Drift for loosening fitting sleeves in flex disks.

WF58.50-P-4110-01A

 Fit on propeller shaft at stiffener arm.



*BA41.10-P-1002-01A

106 A

Propeller shaft center support bearing

 Installation: Only tighten the bolts of the propeller shaft intermediate bearing after attaching the flexible coupling to the rear axle differential.



*BA41.40-P-1001-01A

106c

Propeller shaft clamp nut

Model 202 up to approx. 10/95

 Open-end wrench 46 mm

*126589000100

 Open-end wrench 41 mm

*201589000100



*BA41.10-P-1003-01A



Clamp connection of propeller shaft

Model 202:

Converted to flexible connection.

BT41.10-P-9110-01DA

110b

Parking brake cables from automatic cable adjuster or idler lever, releasing and attaching

See: 

Remove/install rear brake control cable

AR42.20-P-0525A

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

111e

Brake hose

Detach brake hose from floorpan.

 Seal line connections immediately with plugs. The brake fluid reservoir must not run completely empty.

 Box-end wrench attachment

*000589750300

 Installation: The brake hoses (111e) must not be twisted after being tightened (danger of cracking).



*BA42.10-P-1001-04A

 Installation: Bleed brake system

AR42.10-P-0010A



Brake fluid notes

AH42.50-P-0001-01A



Notes on installing brake hoses

AH42.10-P-9406-01A



Notes on repairs to brake system

AH42.00-P-0003-01A

115

Remove fuel pump assembly from rubber rings and tie into place with wire

140

Shield on fuel pump assembly

a

Disconnect, connect 2-pin fuel pump wiring harness connector

Engine 104, 111

AR47.20-P-5713D

HS

Hydraulic line

Only Model 202 to 05/94 with ASD

 Removal: Plug threaded sockets on ring cylinder and line.

L6

Rear axle rpm sensor

Vehicles with ABS:

ra42001240714x

 Clean magnetic tip, replace O-ring.

L6/3, L6/4

Remove/install left rear rpm sensor and right rear rpm sensor

Vehicles with ASR up to 05/94

ra42002020820x

Vehicles with ASR, ETS, ESP as of 06/94

AR42.40-P-0820A

X33/17

Rear headlamp range adjustment connector

Model 170: Vehicles with Xenon headlamps

X33/17

Rear ADS/headlamp range adjustment connector

Models 202, 208: Vehicles with Xenon headlamps

X62/1, X62/2

Left rear rpm sensor / brake wear indicator connector

 If installed

X62/11

Rear axle ABS rpm sensor connector (2-pin)

 If installed

Number

Designation

Model 170

Model 202 without
level adjustment

Model 202
with
level control

BA32.20-P-1002-04C

Self-locking nut, linkage rod to track control arm

Nm

20

20

20

Number

Designation

Model 208
without level control

Model 208
with
level control

BA32.20-P-1002-04C

Self-locking nut, linkage rod to track control arm

Nm

20

20

Number

Designation

Model 202 with level control

Model 208 with level control

BA32.30-P-1003-01B

Self-locking nut, ride-height control strut
to track control arm

Nm

55

55

Number

Designation

Model 170

Model 202

Model 208

BA32.25-P-1003-03A

Self-locking nut for attaching shock absorber to spring control arm

–

Stage 1

Nm

55

55

55

Stage 2

°

-

-

-

M10

Nm

-

-

-

Number

Designation

Model 170

Model 202

Model 208

BA35.10-P-1001-01A

Self-locking bolt, front rear axle carrier rubber mount to frame floor

–

Nm

90

90

90

with bolt Flange Ø 24 mm

Stage 1

Nm

-

-

-

Stage 2

°

-

-

-

with bolt flange Ø 26 mm

Stage 1

Nm

-

-

-

Stage 2

°

-

-

-

BA35.10-P-1002-01A

Self-locking bolt, rear axle carrier rear rubber mount to frame floor

–

Nm

90

90

90

with bolt Flange Ø 24 mm

Stage 1

Nm

-

-

-

Stage 2

°

-

-

-

with bolt flange Ø 26 mm

Stage 1

Nm

-

-

-

Stage 2

°

-

-

-

Number

Designation

Model
170

Model
202

BA35.31-P-1002-02A

Oil filler screw, differential

Nm

50

50

Number

Designation

Model
208

BA35.31-P-1002-02A

Oil filler screw, differential

Nm

50

Number

Designation

Model
170

Model
202

Model
208

BA41.10-P-1002-01A

Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential.

M10

Nm

40

40

40

M12

Nm

60

60

60

BA41.10-P-1003-01A

Clamping nut of propellor shaft

Nm

-

40

-

Number

Designation

Model 170

Model 202

Model 208

BA41.40-P-1001-01A

Bolt, propeller shaft center support bearing to frame floor assembly

Self-tapping screw

Nm

-

-

-

Bolt with washer

Nm

25

25

25

Bolt with collar and self-centering tip

Nm

30

30

30

Bolt with collar and without self-centering tip

Nm

-

-

-

Number

Designation

Model
170

Model
202

Model
208

BA42.10-P-1001-04A

Brake pipe to brake hose

Nm

14

14

14

Number

Designation

Model 170

BA61.10-P-1001-01A

Self-locking bolt connecting rear cross strut to frame floor

Nm

60

Number

Designation

Model
208.435/445/
447/465/470

BA61.10-P-1003-01C

Self-locking bolt connecting rear cross strut to frame floor

Nm

60

Number

Designation

Model 202.018/020/
022/120/121/125, with (code 211) ASD

Model 202.018/078/
120/121/122/
125/182 except (code 450) taxi version,
model 202.018/120/
121/125 without
(code 211) ASD,
model 202.180

Model 202.018/078/
120/121/122/
125/182, without (code 211) ASD, with (code 450) taxi version

BF35.31-P-1001-01D

Filling capacity

Differential

Liters

1.1

0.7

1.1

Specifications for Operating Fluids

Sheet



BB00.40-P-0235-00A

BB00.40-P-0235-00A

Sheet

BB00.40-P-0235-07A

BB00.40-P-0235-07A

BB00.40-P-0235-07A

Number

Designation

Model 202.020/022/
023/024/025/
026/028/029/
080/081/082/
083/086/087/
088/089/128/
188 without
(code 211) ASD,
model 202.085 with automatic 5-speed transmission,
model 202.134/194
except (code 450)
taxi version

Model 202.033/093/
133/193
Model 202.085 with manual 5-speed transmission,
Model 202.134/194
with (Code 450)
Taxi version

BF35.31-P-1001-01D

Filling capacity

Differential

Liters

1.1

1.1

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-00A



Sheet

BB00.40-P-0235-07A

BB00.40-P-0235-07A

Number

Designation

Model 170.435

Model 170.444/445/447/
449

Model
170.465/466

BF35.31-P-1001-01F

Filling capacity

Differential

Liters

0.7

1.1

1.1

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

BB00.40-P-0235-07A

BB00.40-P-0235-07A

Number

Designation

Model 208.335/344/345/
347/348/435/444/445/447/448

Model
208.365/ 370/465/470

Model
208.374/474

BF35.31-P-1001-01H

Filling capacity

Differential

Liters

1.1

1.1

1.6

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

BB00.40-P-0235-07A

BB00.40-P-0235-07A

Number

Designation

Order number

BR00.45-Z-1061-01A

Sealant, Omnifit 100H (50 g)

A 002 989 23 71

BR00.45-Z-1046-04A

Loctite 7063 cleaning spray (150 ml)

A 001 986 71 71 10