Replace radial sealing ring at drive pinion gear (with rear axle differential installed)

AR35.31-P-0530DA

Replace radial sealing ring at drive pinion gear (with rear axle differential installed)

20.6.11

21.6.11

Value modified: Filling capacity

Model 203.040/042/043/046/052/081/084/087/092/240/242/243/246/252/281/284/287/292/707/730/731/740/742/743/746, Model 203.004/061/204/261, as of 09/2002, Model 203.007/207 without taxi version

*BF35.31-P-1001-01K

 

Remove/install

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Raise vehicle

AR00.60-P-1000P

2

Drain oil from rear axle differential

AR35.31-P-0520-06I



Universal hypoid gear oils (SAE 85 W-90)

Sheet 235.7

BB00.40-P-0235-07A

 On rear axle differentials dia. 187 mm, dia. 198 mm up to production date 18.1.04 new oil filler and oil drain screws must be used.





Oil filler/drain screw on rear axle differential modified

up to 18.1.04

BT35.31-P-0015-01A

 Oil drain screw, rear axle differential

*BA35.31-P-1002-02B

 Torque wrench

*001589662100

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

Omnifit sealing compound 100H (50 g)

*BR00.45-Z-1061-01A

3

Remove exhaust system (105) from flange connection

AR49.10-P-7000PM

4

Remove exhaust heat shield (105c)

5

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

 Installation: Attach flexible coupling to rear axle differential first before tighten bolts of propeller shaft intermediate bearing (106a).

 Bolt, propeller shaft intermediate bearing to frame floor assembly

*BA41.40-P-1001-01A

 Torque wrench

*001589662100

6

Remove rear propeller shaft (106) from rear axle differential

 The flexible coupling remains on the rear propeller shaft (106).

AR41.10-P-0050-03EA

 If the fitting sleeves are stuck:



Loosen fitting sleeves on flexible couplings.

AR41.10-P-0050-09DA



Drift for loosening fitting sleeves in flex disks.

WF58.50-P-4110-01A

Attach rear propeller shaft (106) to rear axle differential

AR41.10-P-0050-04EA

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

*BA41.10-P-1002-01A

 Torque wrench

*001589662100

7

Detach rear propeller shaft (106) from front propeller shaft (106c)

 Installation: Observe markings:



Connect sections of propeller shaft

AR41.10-P-0050-05DA



Long-life grease (NLGI grade 2)

Sheet 266.2

BB00.40-P-0266-02A



Measure

8.1

Measure and note down total friction torque of drive pinion

On rear axle differential dia. 198 mm

AR35.31-P-0530-04P

 Move the rear axle shafts (37) to as close to horizontal as possible. To do this, compress both rear axle springs using a spring compressor if necessary.

 Installation: The total friction torque measured at the drive pinion gear during removal must be set again.

 Torque meter

*001589492100

 Connection piece

*100589025900

 Socket

*203589010900

9.1

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

On rear axle differential dia. 198 mm



Pressing bush for wrench socket

WF58.50-P-3531-02A

 Do not remove the collar protection when loosening the twelve-point/hexagon collar nut (40).

 For better control when loosening the twelve-point/hexagon collar nut (40), press a shop-made bush into the commercially available socket.

 Pin wrench

*129589010700

 Socket

*203589010900

 Torque wrench

*001589672100

 Installation: Fit a new twelve-point / hexagon collar nut (40) and tighten in stages until the previously measured friction torque is obtained.



Secure twelve-point and hexagon collar nut on drive pinion joint flange

AR35.31-P-0530-01B



Chisel for securing collar nut on joint flange

WF58.50-P-3531-01A

9.2

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

 On rear axle differential dia. 187 mm, dia. 200 mm

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

 Collar nut of joint flange to drive pinion gear

*BA35.31-P-1001-01A

 Pin wrench

*129589010700

Rear axle differential, 187 mm dia:

 Socket

*126589020900

Rear axle differential dia. 200 mm:

 Socket

*203589010900

 Torque wrench

*001589672100

 Installation: Install a new twelve-point / hexagon collar nut (40), see:



Secure twelve-point and hexagon collar nut on drive pinion joint flange

AR35.31-P-0530-01B



Chisel for securing collar nut on joint flange

WF58.50-P-3531-01A

10

Detach joint flange (41).

 Puller

*129589013300

11

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

 Coat sealing lip with universal hypoid gear oil.



Universal hypoid gear oils (SAE 85 W-90)

Sheet 235.7

BB00.40-P-0235-07A

 Rear axle differential dia. 198 mm, dia. 200 mm:

 Drift

*140589131500

 Rear axle differential dia. 187 mm

 Drift

*208589001500

12

Replace breather

 To prevent damage to the inside of the rear axle differential, make sure that no dirt penetrates the breather housing opening.

 Clean housing surface around the breather before removal using suitable cleaning agent.

Rear axle differential dia. 198 mm:

Remove breather from rear axle differential.

 Rear axle differential breather

*BA35.31-P-1003-02B

 Torque wrench

*001589662100

Rear axle differential dia. 187 mm, dia. 200 mm:

 To install a new breather, you must first remove the rear axle differential. Refer to:



Remove/install rear axle differential

AR35.31-P-0520P

 Drive breather uniformly out of the housing using suitable tool (e.g. drift, screwdriver).

 Installation: Drive the new breather evenly into the housing using a suitable drift.

 Installation: Ensure breather is correctly seated.

13

Install in the reverse order



Checking

14

Check oil level in rear axle differential and correct if necessary

 In the interest of better fuel economy, avoid mixing old universal hypoid gear oil with new FE hypoid gear oil.

AR35.31-P-0520-03I



Universal hypoid gear oils (SAE 85 W-90)

Sheet 235.7

BB00.40-P-0235-07A

 On rear axle differentials dia. 187 mm, dia. 198 mm up to production date 18.1.04 new oil filler and oil drain screws must be used.





Oil filler/drain screw on rear axle differential modified

up to 18.1.04

BT35.31-P-0015-01A

 Oil filler screw for rear axle differential

*BA35.31-P-1001-02B

 Filling capacity of rear axle differential

*BF35.31-P-1001-01K

 Torque wrench

*001589662100

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

Omnifit sealing compound 100H (50 g)

*BR00.45-Z-1061-01A

15

Check rear axle differential for leaks

 Carry out visual inspection.

Number

Designation

Model
203.006/007/
016/064/206/
207/216/264/
706/707,

Model
203.004/204
with code 450
up to 08/2002

Model
203.008/020/
040/042/043/
046/052/054/
056/081/084/
087/092/208/
220/240/242/
243/246/252/
254/256/281/
284/287/292/
708/730/731/
742/743/740/
746/756,
Model
203.004/061/
204/261
as of 09/2002

BA35.31-P-1001-01A

Collar nut, joint flange to drive pinion

Nm

> 180

150

Number

Designation

Model
209.308/
320/341/
342/343/
354/356/
361/420/
441/442/
454/456/
461

BA35.31-P-1001-01A

Collar nut, joint flange to drive pinion

Nm

150

Number

Designation

Model
203.006/007/
008/064/206/
207/208/264/
706/707/708/
764,

Model
203.004/204
with code 450
up to 08/2002

Model
203.007/207/
with code 450

BA35.31-P-1001-02B

Oil filler screw, rear axle differential

Nm

50

BA35.31-P-1002-02B

Oil drain screw, rear axle differential

Nm

50

BA35.31-P-1003-02B

Breather, rear axle differential

Nm

25

Number

Designation

Model
209.308/320/
354/356/420/
454/456

BA35.31-P-1001-02B

Oil filler screw, rear axle differential

Nm

50

BA35.31-P-1002-02B

Oil drain screw, rear axle differential

Nm

50

Number

Designation

Model
203

Model
209

BA41.10-P-1002-01A

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

M10

Nm

40

36

M12

Nm

60

58

Number

Designation

Model 203

Model 209

BA41.40-P-1001-01A

Bolt, propeller shaft intermediate bearing to frame floor assembly

Self-tapping screw

Nm

-

-

Bolt with washer

Nm

-

-

Bolt with collar and self-centering tip

Nm

30

30

Bolt with collar and without self-centering tip

Nm

-

-

Number

Designation

Model
203.006/008/054/
056/064/206/208/
254/256/264/706/
708/756/764,

Model
203.004/204
with taxi version
code 450, up to 08/2002,

Model
203.007/207
with taxi version
code 450

Model
203.040/042/043/
046/052/081/084/
087/092/240/242/
243/246/252/281/
284/287/292/707/
730/731/740/742/
743/746,
Model
203.004/061/204/
261, as of 09/2002,
Model
203.007/207
without taxi version

BF35.31-P-1001-01K

Filling capacity

Rear axle center assembly

Liters

1.1

0.95

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

BB00.40-P-0235-07A

Number

Designation

Model
209.308/354/
356/365/454/
456/465

BF35.31-P-1001-01K

Filling capacity

Rear axle center assembly

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

Cleaning spray, Loctite 7063 (150ml)

A 001 986 71 71 10