Remove/install complete rear axle

AR35.10-Y-0010IND

Remove/install complete rear axle

27.01.2020

Rear axle

400.756 in model 831.001/002/005

Rear axle removal procedure

1

Drain plug

2

Axle shaft

3

Rear brake drum

4

Propeller shaft

5

Stabilizer bar

6

Stabilizer link rod

7

Drive head unit

8

Trolley jack

9

U-bolts mounting nuts

10

Rear axle

12

U-bolt

11

Special tool axle work stand 090 589 15 31 00

13

Spring seat

Rear axle installation procedure

A

U-bolt nut 1

B

U-bolt nut 2

C

U-bolt nut 3

D

U-bolt nut 4

6

Stabilizer link rod

7

Drive head unit

8

Trolley jack

12

U-bolt

13

Spring seat

2

Axle shaft

3

Rear brake drum

4

Propeller shaft

5

Stabilizer bar

1

Drain plug

14

Refill plug

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on compressed air connection systems

AH00.18-N-0001-01A



Remove

1

Discharge compressed air system.

2

Remove tires from both the sides of the rear axle.

AR40.10-Y-1100IND

 Support the chassis on rigid jack.

3

Drain the differential oil from the axle housing by removing the drain plug (1).

 Collect the oil in a suitable container.

4

Remove axle shaft (2) from the wheel hub on both the sides.

5

Remove the rear brake drum (3) on both sides.

6

Remove rear wheel hubs on both sides of the rear axle.

AR35.20-Y-0310D

7

Remove rear foundation brake components.

AR42.15-Y-1052B

8

Remove propeller shaft (4) from differential input flange by removing the bolts and nuts 4 nos.

9

Remove stabilizer bar both side mounting bolts from U-bolts mounting.

10

Remove stabilizer bar (5) mounting bolts both side from stabilizer link rod.

 In case of difficult remove stabilizer link rod (6) mounting nut from chassis.

11

Attach drive head unit (7) flange to the special tool fixture and remove it from the rear axle housing.


Be cautious while removing the drive head from the rear axle housing.
To avoid damaging the rear axle housing due to heavy load of drive head.

 Support fixture

*090589086200

12

Supports axle using trolley jack (8) to relieve load from leaf spring assemblies.

13

Remove U-bolts mounting nuts (9) from leaf spring.

 Carefully lower the rear axle (10) away from the springs and withdraw the rear axle housing from the vehicle.

14

Place the rear axle properly on the special tool axle work stand (11).

 If required, remove the spring seat (13) and U-bolt (12) from the leaf spring.

 Assembly stand

*090589153100



Install

15

Place and support the axle assembly under the vehicle using trolley jack (8).

 If removed, place the spring seat (13) and U-bolts (12) over the leaf spring.

16

Raise the axle unit to proper seat under the leaf spring using trolley jack.

17

Install and tighten U-bolt nuts on both the sides.

 Ensure that the U-bolt nuts are tightened as shown in the illustration.

 Tighten U-bolt nuts

*BA35.10-Y-1001-03E

18

Apply recommended sealant on the installation face between drive head and axle housing.


Installation surface of drive head and axle housing must be kept clean (free of dust, dirt, oil etc).
To ensure perfect sealing and to avoid lubricant leakage.

Sealant

*BR00.45-Z-1119-01A

19

Install the drive head unit (7) to the rear axle housing and detach the special tool drive head removal fixture.

 Drive head unit to rear axle housing

*BA35.10-Y-1002-03E

 Support fixture

*090589086200

20

Install the stabilizer link rod (6) to the chassis and tighten the mounting nut.

 Stabilizer link rod to chassis

*BA35.10-Y-1003-03E

21

Install stabilizer bar to the stabilizer link rod.

 Stabilizer bar to the stabilizer link rod

*BA35.10-Y-1004-03E

22

Install stabilizer bar (5) other end to the U-bolts side and tighten the mounting bolt and nut.

 Stabilizer bar to the U-bolts

*BA35.10-Y-1005-03E

23

Install propeller shaft (4) to differential input flange by tightening the bolts and nuts 4 nos.

 Propeller shaft to differential input flange

*BA35.10-Y-1006-03E

24

Install rear foundation brake components.

AR42.15-Y-1052B

25

Install the rear wheel hubs.

AR35.20-Y-0310D

26

Install rear brake drum (3) to rear wheel hub on both the sides of the rear axle.

27

Install rear tires to both sides of the rear axle.

AR40.10-Y-1100IND

28

Lift the rear axle to remove the chassis stands from vehicle.

29

Apply recommended sealant to the axle shafts and then install axle shaft (2) to the wheel hub on both sides.


Installation surface of axle shaft and wheel hub assembly must be kept clean (free of dust, dirt, oil etc).
To ensure perfect sealing and avoid leakage.

 Axle shaft to the wheel hub

*BA35.10-Y-1007-03E

Sealant

*BR00.45-Z-1119-01A

30

Apply recommended sealant to bolt threads.

Loctite 262

*BR00.45-Z-1059-02A

31

Tighten the drain plug (1) to the axle housing.

 Drain plug to axle housing

*BA35.10-Y-1008-03E

32

Remove the refill plug (14) and fill the specified quantity of oil in the rear axle and tighten the refill plug.

 Tighten refill plug

*BA35.10-Y-1009-03E

 Rear axle oil - AAM 7.14

*BF35.10-Y-1001-01B

 Rear axle

Number

Designation

Rear axle 400.756 in model 831.001/002/005

BA35.10-Y-1001-03E

Tighten U-bolt nuts

Nm

340

 Rear axle

Number

Designation

Rear axle 400.756 in model 831.001/002/005

BA35.10-Y-1002-03E

Drive head unit to rear axle housing

Nm

81­101

 Rear axle

Number

Designation

Rear axle 400.756 in model 831.001/002/005

BA35.10-Y-1003-03E

Stabilizer link rod to chassis

Nm

119.6­204

 Rear axle

Number

Designation

Rear axle 400.756 in model 831.001/002/005

BA35.10-Y-1004-03E

Stabilizer bar to the stabilizer link rod

Nm

106

 Rear axle

Number

Designation

Rear axle 400.756 in model 831.001/002/005

BA35.10-Y-1005-03E

Stabilizer bar to the U-bolts

Nm

187.68­331.2

 Rear axle

Number

Designation

Rear axle 400.756 in model 831.001/002/005

BA35.10-Y-1006-03E

Propeller shaft to differential input flange

Nm

59.8­90

 Rear axle

Number

Designation

Rear axle 400.756 in model 831.001/002/005

BA35.10-Y-1007-03E

Axle shaft to the wheel hub

Nm

82­101

 Rear axle

Number

Designation

Rear axle 400.756 in model 831.001/002/005

BA35.10-Y-1008-03E

Drain plug to axle housing

Nm

54

 Rear axle

Number

Designation

Rear axle 400.756 in model 831.001/002/005

BA35.10-Y-1009-03E

Tighten refill plug

Nm

54

 Rear axle

Number

Designation

Rear axle 400.756 in model 831.001/002/005

BF35.10-Y-1001-01B

Rear axle oil - AAM 7.14

Litre

6.5

Sheet

BB00.40-P-0235-01A

Repair materials

Number

Designation

Order number

BR00.45-Z-1059-02A

Loctite 262

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1119-01A

Sealant

Loctite 515