Remove/install complete rear axle

AR35.10-P-0010T

Remove/install complete rear axle

17.10.11

17.6.11

Value changed: filling capacity

Model 211 except 211.077/277

*BF35.31-P-1003-01L

 

Remove/install

 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

 Danger!

Risk of injury caused by body parts being jammed or crushed. Risk of injury to skin and eyes caused by brake fluid spraying out at high pressure when working on the SBC brake system

Deactivate SBC brake system using STAR DIAGNOSIS.

AS42.46-Z-0001-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 Installation

Caution, important note: The threads in the frame floor assembly must be recut and blown out, as any adhesive residue in a thread will prevent the bolt's necessary preload force from being achieved, despite having reached the specified torque and specified angle of rotation.
If this is not observed then the faulty bolt pretension force will cause transverse forces to be applied to the bolt, which may cause the bolt to fracture



While working on the rear axle, care must be taken to ensure that the surface of aluminum components do not get any scratches, cracks and notches. Otherwise the service life of the parts will be affected

 Installation

Only tighten nuts and bolts of chassis components when vehicle is in a ready-to-drive condition.

1

Deactivate SBC brake system using STAR DIAGNOSIS.

Vehicles with Sensotronic Brake Control (SBC)

The following steps should be run through in STAR DIAGNOSIS:

Select menu item "SBC Sensotronic Brake Control"/"Deactivate 'SBC' system".

Then process all the individual steps from top to bottom.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

2

Empty air springs (6i) completely using STAR DIAGNOSIS

Vehicles with AIRmatic (semi-active air suspension), code 489

AR32.22-P-1500-04T



Notes on AIRmatic

Vehicles with AIRmatic (semi-active air suspension), code 489

AH32.22-P-1000-02T



*211589000900



Fill the air spring in vehicle riding height position

Vehicles with AIRmatic (semi-active air suspension), code 489

AR32.22-P-1500-03T

Installation: The filling process for the air springs must be observed, otherwise the air springs will be irreparably damaged.



*BA32.25-P-1008-04B



*BA32.25-P-1009-04B

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

Electronic inclinometer
gotis://F_40.2_02.0



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

3.1

Remove rear muffler

Model 211.004/ 006/ 206/ 007/ 008/ 208

AR49.10-P-4951T

Model 211.020/ 220/ 022/ 222/ 084/ 089/ 284/ 289

AR49.10-P-4951TI

Model 211.029

AR49.10-P-4951TJ

3.2

Remove exhaust system from flange connection back

Model 211.016 /216

AR49.10-P-7280T

Model 211.028

AR49.10-P-7280TC

3.3

Detach complete exhaust system

Model 211.061 /065 /070 /076 /077 /261 /265 /270 /276 /277 /080 /082 /083 /280 /282 /283

AR49.10-P-7000TB

Model 211.041 /241 /042 /242

AR49.10-P-7000TK

Model 211.054 /056 /072 /087 /090 /092 /254 /256 /272 /287 /290 /292

AR49.10-P-7000TS

3.4

Remove exhaust system from pipe connection

Model 211.023 /026 /223 /226

AR49.10-P-7281T

4

Remove rear section components on underfloor paneling

AR61.30-P-1001T

5

Unhook brake cables from automatic slack adjuster of parking brake

AR42.20-P-0525T

6

Detach propeller shaft (106) from flange on rear axle center assembly (50)

 Apply color markings indicating the position of the propeller shaft relative to the transmission, the rear axle differential and the propeller shaft center support bearing (106a) to ensure that the components are fitted at the correct ex-factory positions on reinstallation, otherwise drive line vibrations may occur.

AR41.10-P-0050-04I

 Flex disk remains on propeller shaft.



*BA41.10-P-1002-01A

7

Detach fitting sleeves of flexible coupling on flange of rear axle center assembly (50)

AR41.10-P-0050-09DA



Drift for loosening fitting sleeves in flex disks.

WF58.50-P-4110-01A

8

Remove bolts from propeller shaft intermediate bearing (106a) and remove rear part of propeller shaft (106)

 Installation: Assemble propeller shaft in correct position. Do not tighten the bolts of the propeller shaft center support bearing until you have secured the flexible coupling to the rear axle differential (50).

AR41.10-P-0050-05DA



*BA41.40-P-1001-01A



Long-life grease (NLGI grade 2)

Sheet 266.2

BB00.40-P-0266-02A

9

Remove rear wheels



Remove/install wheels, rotate if necessary

AP40.10-P-4050Z

10.1

Remove left and right rear brake calipers

For repair work on the tank or rear axle.

Floating caliper

AR42.10-P-0080R

Fixed caliper

AR42.10-P-0080RA

 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

10.2

Detach left and right rear brake hose (51) from the brake lines

For bodywork or replacement of rear axle assembly.

AR42.10-P-0013T

 Seal off line connections immediately with plugs. The brake fluid expansion reservoir must not be allowed to run completely empty.



Brake fluid notes

AH42.50-P-0001-01A



Notes on installing brake hoses

AH42.10-P-9406-01A

 When releasing or fastening the brake line on the brake hose make sure that its bracket is not twisted. Use an open-end wrench as a countersupport on the sides of the brake hose fitting.



*000589750300



*129589009100

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



*BA42.10-P-1001-04A

11

Remove fender liners from rear fenders

Vehicles with AIRmatic (semi-active air suspension), code 489

AR88.10-P-1400T

12

Disconnect electrical connectors of brake and chassis components at the rear axle

Vehicles with AIRmatic (semi-active air suspension), code 489

AR32.22-P-1500-01TH

13

Detach left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4) from the wheel carriers

Vehicles without AIRmatic

 Unclip electric feed lines of rpm sensor from all retaining clamps and tie up rpm sensor to one side.



*BA42.30-P-1001-02A

14

Disconnect electrical connector from right rear brake pad contact sensor (S10/4)

Vehicles without AIRmatic

15

Detach electrical feed line (1) of right rear brake pad contact sensor (S10/4)

Vehicles without AIRmatic

 Unclip electrical feed line from retaining clamps and tie up to one side.



*BA42.10-P-1002-12H

16.1

Use assembly lever to pry left and right air springs (6i) off the frame floor

Vehicles with AIRmatic (semi-active air suspension), code 489

 The retaining clips of the air springs are destroyed in the process.

 Installation: Slide on the air springs until the new retaining clips can be heard engaging in the frame floor. The air springs should be aligned and should not have kinks.

16.2

Remove left and right rear springs

Model 211.0 without AIRmatic

Model 211.0 except 4MATIC

AR32.20-P-0230P

Model 211.08 /09

AR32.20-P-0230T

17

Remove damper (6j) at left and right from spring control arms

Vehicles with AIRmatic (semi-active air suspension), code 489



*BA32.25-P-1002-03G

18

Drain fuel tank.

Vehicles with diesel engine except engine 629

AR47.10-P-4001T

Engine 629

AR47.10-P-4001TJ

Vehicles with gasoline engine

AR47.10-P-4001TB

19

Remove filler hose (17) of fuel tank

20

Install guard plates (01) to protect brake disk cover panels

AR42.00-P-0100-01A



*220589013100

21

Lower rear axle.

 Installation: Recut and blow out the threads in the frame floor assembly to ensure a perfect threaded connection.

AR35.10-P-0020-01T

 Use new bolts.



*BA35.10-P-1001-01E



*BA35.10-P-1002-01E

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

22

Replace retaining clips of air springs (6i)

Vehicles with AIRmatic (semi-active air suspension), code 489

AR32.22-P-1500-02T



Checking

23

Check rear axle for damage, replace damaged parts

24

Check condition of air springs (6i)

Vehicles with AIRmatic (semi-active air suspension), code 489

AR32.22-P-1500-05T

25

Install in the reverse order

26

Check oil level in rear axle center assembly (50) 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-0520-03I



*BF35.31-P-1001-01L



*BF35.31-P-1002-01L



*BF35.31-P-1003-01L



*BF35.31-P-1004-01L



*BF35.31-P-1006-01L



*BA35.31-P-1002-02A

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

Sealant, Omnifit 100H (50 g)

*BR00.45-Z-1061-01A



Oil filler/drain screw on rear axle differential modified

Phased in as of 19.01.04

BT35.31-P-0015-01A

27.1

Bleed brake system with STAR DIAGNOSIS

Vehicles with Sensotronic Brake Control (SBC)

AR42.10-P-0012R

The following steps should be run through in STAR DIAGNOSIS:

Select menu item "initial startup after repair"/"after opening or exchanging one or more brake hoses".

Then process all the individual steps from top to bottom.

 When performing the bleeding operation always observe the instructions in the document "Bleeding brake system using STAR DIAGNOSIS".

STAR DIAGNOSIS diagnosis system

27.2

Bleed brake system

Vehicles with Adaptive Brake (ABR)

AR42.10-P-0010T

28

Perform wheel alignment check

AR40.20-P-0200T

Number

Designation

Model
211

BA41.10-P-1002-01A

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

M10

Nm

40

M12

Nm

60

Number

Designation

Model 211

BA41.40-P-1001-01A

Bolt, propeller shaft center support bearing to frame floor assembly

Self-tapping screw

Nm

25

Bolt with washer

Nm

-

Bolt with collar and self-centering tip

Nm

-

Bolt with collar and without self-centering tip

Nm

-

Number

Designation

Model
211
with SBC

Model
211
with ABR [Adaptive Brake]

BA42.10-P-1001-04A

Brake pipe to brake hose

Nm

18

18

Number

Designation

Model
211
except model
211.076/077/
276/277

Model
211.076/077/
276/277

BA42.10-P-1002-12H

Bolt, brake pad contact sensor to brake caliper

Nm

8

8

Number

Designation

Model 211

BA42.30-P-1001-02A

Self-locking bolt of rear axle rpm sensor to wheel carrier

Nm

8

Number

Designation

Model 211

BA35.10-P-1001-01E

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

Stage 1

Nm

90

Stage 2

°

60

BA35.10-P-1002-01E

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

Stage 1

Nm

90

Stage 2

°

60

Number

Designation

Model
211.0 with code 489a
AIRmatic

Model 211.2/6

BA32.25-P-1002-03G

Self-locking nut to
spring control arm shock absorber

M10

Stage 1

Nm

50

50

Stage 2

°

90

90

Number

Designation

Model
211

BA35.31-P-1002-02A

Oil filler screw, differential

Nm

50

Number

Designation

Model 211
AIRmatic

BA32.25-P-1008-04B

Nut, rear air spring at spring control arm

Nm

150

BA32.25-P-1009-04B

Air suspension pressure line at rear axle distributor

Nm

2

Number

Designation

Model
211 except 211.077/277

Model
211.077/277,
model
230.470/472/
474/479

BF35.31-P-1001-01L

Filling capacity

210 mm dia.rear axle differential in rear axle differential 210E

Liters

1,6

-

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

-

BF35.31-P-1002-01L

Filling capacity

Rear axle differential dia. 198 mm

Liters

1.1

-

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

-

BF35.31-P-1003-01L

Filling capacity

Differential Ø 187 mm

Liters

0.95

-

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

-

BF35.31-P-1004-01L

Filling capacity

Differential Ø 215 mm

Liters

1.2

1.2

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

BB00.40-P-0235-61A

BF35.31-P-1006-01L

Filling capacity

200 mm dia. rear axle differential in rear axle differential 200FE

Liters

1,1

-

Specifications for Operating Fluids

Sheet

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