Install new radial sealing ring at drive pinion gear (with differential installed)

AR35.31-P-0530D

Install new radial sealing ring at drive pinion gear (with differential installed)

30.8.10

 

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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Raise vehicle

2

Drain oil from rear axle differential

Model 170, 202, 208

AR35.31-P-0520-06A

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

Sealant, Omnifit 100H (50 g)

*BR00.45-Z-1061-01A

 Oil drain screw

*BA35.31-P-1003-02A



Oil filler/drain screw on rear axle differential modified

Phased in as of 19.01.04

BT35.31-P-0015-01A

3

Remove exhaust system (105) from flange connection

Refer to: Remove/install exhaust system complete: 

Model 170 with engines 111.943/946/973

AR49.10-P-7000G

Model 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 except engine 113.984 in model 208.474

AR49.10-P-7000AU

Model 208.474 with engine 113.984

Model 208 with engine 111.945/ 975

AR49.10-P-7000DA

Model 208 with engine 111 except engine 111.945/ 975

4

Remove exhaust heat shield (105c)

5.1

Loosen propellor shaft clamping nut (106c)

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

6

Remove bolts for propeller shaft intermediate bearing (106a).

 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

7

Remove rear propeller shaft (106) from rear axle differential

 Flex disk remains on propeller shaft.

If the fitted sleeves are jammed: 

Loosen fitting sleeves on flexible couplings.

AR41.10-P-0050-09DA



Drift for loosening fitting sleeves in flex disks.

WF58.50-P-4110-01A

 Push rear propeller shaft forwards out of the centering on the drive pinion and remove towards the rear.

 Installation: Pay attention to existing marking.

AR41.10-P-0050-05DA



*BA41.10-P-1002-01A

8.1

Remove cover of fuel pump assembly (140)

Vehicles with gasoline engine

9

Detach rear axle shafts (37) from the connecting flanges

 Move the rear axle shaft into approximately the horizontal position and push together.

Tie rear axle shafts securely to the rear axle carrier.

 Installation: Replace self-locking multi-point or hexagon socket bolts and washers.

Lightly oil bolts at thread and bolt head contact surface.



*BA35.30-P-1002-01A



Measure

10

Measure and note friction torque

Model 170, 202, 208

AR35.31-P-0530-04B

 Torque meter

*001589492100

 Connection piece

*100589025900

 27 mm socket for rear axle differential dia. 168 mm

*201589000900

 30 mm socket for rear axle differential dia. 185 mm

*126589020900

Socket wrench bit 41 mm hexagon 3/4 inch square 41 mm for 198 mm dia. rear axle differential and 210 mm dia. rear axle differential in rear axle differential 210E

11

Loosen and remove twelve-point collar nut or hexagon collar nut (40)

 Do not remove the collar protection when loosening twelve-point or hexagon collar nut.

 Pin wrench

*129589010700

 27 mm socket for rear axle differential dia. 168 mm

*201589000900

 30 mm socket for rear axle differential dia. 185 mm

*126589020900

41 mm socket wrench bit for 198 mm dia. rear axle differential and 210 mm dia. rear axle differential 210E: 

 To improve guidance when loosening the hexagon collar nut, press a shop-made bush into the commercially available socket wrench bit.

 Installation: Replace twelve-point or hexagon collar nut and tighten in stages until the previously measured friction torque is obtained.

 Observe minimum tightening torque; if necessary if tightening torque is not achieved: 

*BA35.31-P-1001-01A

 Rear axle differential dia. 168 mm, dia. 185 mm, dia. 198 mm: Install new elastic distance sleeve, refer to Disassemble/assemble rear axle differential, adjust gear set: 

Differential Ø 168 mm

AR35.31-P-0550B

Differential Ø 185 mm

AR35.31-P-0550C

Rear axle differential dia. 198 mm

AR35.31-P-0550A

 Rear axle differential dia. 210 mm in rear axle differential 210E
: If the minimum tightening torque is not obtained, install new rear axle differential.

 Installation: Secure twelve-point or hexagon collar nut

AR35.31-P-0530-01B



Chisel for securing collar nut on joint flange

WF58.50-P-3531-01A

12

Detach joint flange (41).

 Use  puller if necessary: 

 Puller

*129589013300



Radial sealing ring and joint flange on drive pinion modified

As of 01.04.98 on model 170, 202, 208 with 185 mm dia. rear axle differential

BT35.31-P-0012-01A



Radial sealing ring and joint flange on drive pinion modified

As of 15.01.02 on model 170, 202, 208 with rear axle differential dia. 185 mm

BT35.31-P-0012-01B



Radial sealing ring and joint flange on drive pinion modified

As of 15.01.02 on model 170, 202, 208 with rear axle differential dia. 198 mm and model 208 with rear axle differential dia. 210 mm in rear axle differential 210E

BT35.31-P-0012-01C

13

Press out radial sealing ring (42) using a suitable tool

 185 mm dia. rear axle differential:
When pressing out ensure that no retaining lug (if present) of the loose pressure plate on the tapered roller bearing is broken off. If necessary, replace and remove lug in rear differential assembly.

 Installation: Replace radial sealing ring and coat sealing lip with universal hypoid gear oil: 



Universal hypoid transmission fluid

BB00.40-P-0235-07A

 Drift for pressing in rear axle differential dia. 168 mm

*201589001500

 Drift for pressing in the previous radial sealing ring version for rear axle differential dia. 185 mm.

*208589001500



Radial sealing ring and joint flange on drive pinion modified

As of 01.04.98 on model 170, 202, 208 with 185 mm dia. rear axle differential

BT35.31-P-0012-01A



Radial sealing ring and joint flange on drive pinion modified

As of 15.01.02 on model 170, 202, 208 with rear axle differential dia. 185 mm

BT35.31-P-0012-01B

 Drift for pressing in the new radial sealing ring version for rear axle differential dia. 185 mm.

*140589141500

 Drift for pressing in the previous radial sealing ring version for 198 mm dia.rear axle differential and 210 mm dia. rear axle differential in rear axle differential 210E

*140589081500



Radial sealing ring and joint flange on drive pinion modified

As of 15.01.02 on model 170, 202, 208 with rear axle differential dia. 198 mm and model 208 with rear axle differential dia. 210 mm in rear axle differential 210E

BT35.31-P-0012-01C

 Drift for pressing in the new radial sealing ring version for 198 mm dia. rear axle differential and 210 mm dia. rear axle differential in rear axle differential 210E

*140589131500

14

Replace breather of rear axle differential



*BA35.31-P-1005-02A

15

Install in the reverse order

16

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.

Model 170, 202, 208 except model 170 with rear axle differential dia. 198 mm

AR35.31-P-0520-03A

Model 170 with rear axle differential dia. 198 mm

 Model 170 rear axle differential filling capacity

*BF35.31-P-1001-01F

 Model 202 rear axle differential filling capacity

*BF35.31-P-1001-01D

 Model 208 rear axle differential filling capacity

*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 screw for rear axle differential

*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

Number

Designation

Model
170

Model
202

Model
208

BA35.30-P-1002-01A

Self-locking bolt, rear axle shaft to connecting flange (thread and bolt head contact surface oiled)

M10

Nm

70

70

70

M12

Nm

-

-

-

Number

Designation

Model
170.435

Model
170.444/
445/447/
449

Model 170.465 /
466

BA35.31-P-1001-01A

Collar nut, joint flange to drive pinion

Nm

>90

> 180

> 180

Number

Designation

Model
202.018/
078/120/
121/122/
125/180/
182 except code 450

Model
202.018/078/
120/121/122/
125/182 with code 450

BA35.31-P-1001-01A

Collar nut, joint flange to drive pinion

Nm

>90

> 180

Number

Designation

Model
202.020/022/
023/024/025/
026/028/029/
033/080/081/
082/083/086/
087/088/089/
093/128/133/
188/193,
202.085 with automatic 5-speed
transmission, 202.134/194 except code 450

Model
202.033/093/
133/193,
202.085 with manual 5-speed
transmission,
202.134/194 with
code 450

BA35.31-P-1001-01A

Collar nut, joint flange to drive pinion

Nm

> 180

> 180

Number

Designation

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

Model 208.365/370/465/
470

Model
208.374

BA35.31-P-1001-01A

Collar nut, joint flange to drive pinion

Nm

> 180

> 180

> 180

Number

Designation

Model
170

Model
202

BA35.31-P-1002-02A

Oil filler screw, differential

Nm

50

50

BA35.31-P-1003-02A

Oil drain screw for rear axle differential

Nm

50

50

BA35.31-P-1005-02A

Breather, rear axle differential

Nm

25

25

Number

Designation

Model
208

BA35.31-P-1002-02A

Oil filler screw, differential

Nm

50

BA35.31-P-1003-02A

Oil drain screw for rear axle differential

Nm

50

BA35.31-P-1005-02A

Breather, rear axle differential

Nm

25

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 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