Remove/install complete rear axle

AR35.10-P-0010TA

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 preload force will cause bending forces to act on the bolt, which could ultimately lead to bolt 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

AR32.22-P-1500-04TA



Notes on air suspension

AH32.22-P-1000-01T



*211589000900

 Installation: The filling process of the air springs should be observed otherwise they will be irreparably damaged:

Charge air springs using STAR DIAGNOSIS in design level.

AR32.22-P-1500-03TA



*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 211.206 /606 /208 /608

AR49.10-P-4951T

Model 211.220 /222 /284 /289 /620

AR49.10-P-4951TI

3.2

Remove exhaust system from flange connection back

Model 211.216 /616

AR49.10-P-7280T

3.3

Detach complete exhaust system

Model 211.261 /265 /280 /282

AR49.10-P-7000TB

Model 211.241 /242

AR49.10-P-7000TK

Model 211.254 /256 /287 /292

AR49.10-P-7000TS

3.4

Remove exhaust system from pipe connection

Model 211.223 /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)

 Flex disk remains on propeller shaft.

AR41.10-P-0050-04I



*BA41.10-P-1002-01A

7

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

If the fitted sleeves are jammed: 

AR41.10-P-0050-09DA



Produce drift for detaching the fitting sleeves in the flexible coupling.

WF58.50-P-4110-01A

8

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

 Apply color markings indicating the position of the propeller shaft relative to the rear axle differential (50) and the propeller shaft center support bearing to ensure that the components are fitted at the correct ex-factory positions on reinstallation, otherwise drive line vibrations may occur.

 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)

BB00.40-P-0266-02A

9

Remove rear wheels



Remove/install wheels

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.



*000589750300



*129589009100

 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.

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



*BA42.10-P-1001-04A



Brake fluid notes

AH42.50-P-0001-01A



Notes on installing brake hoses

AH42.10-P-9406-01A

11

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

 Unclip electrical feed lines of rpm sensors from all retaining clamps and tie rpm sensors to one side.



*BA42.30-P-1001-02A

12

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

13

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

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

*BA42.10-P-1002-12H

14

Pry left and right air spring (6i) off the frame floor using assembly lever

 This destroys the clips on the air springs.

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

15

Detach left and right shock absorbers (6j) from spring control arms



*BA32.25-P-1002-03G

16

Drain fuel tank.

Vehicles with diesel engine

AR47.10-P-4001T

Vehicles with gasoline engine

AR47.10-P-4001TB

17

Remove filler hose (17) of fuel tank

18

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

AR42.00-P-0100-01A



*220589013100

19

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

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

20

Replace retaining clips of air springs (6i)

AR32.22-P-1500-02TA



Checking

21

Check rear axle for damage, replace damaged parts

22

Check condition of air springs

AR32.22-P-1500-05TA

23

Install in the reverse order

24

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

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

Sealant, Omnifit 100H (50 g)

*BR00.45-Z-1061-01A



*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

25.1

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".

25.2

Bleed brake system

Vehicles with Adaptive Brake (ABR)

AR42.10-P-0010T

26

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
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

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

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 211.2/6

BA32.25-P-1002-03G

Self-locking nut to
spring control arm shock absorber

M10

Stage 1

Nm

50

Stage 2

°

90

Number

Designation

Model
211

BA35.31-P-1002-02A

Oil filler screw, differential

Nm

50

Number

Designation

Model 211.2/6

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