Remove/install radial sealing ring of rear axle shaft at rear axle housing

AR35.31-P-0541DA

Remove/install radial sealing ring of rear axle shaft at rear axle housing

31.8.11

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



Notes on repairs to brake system

AH42.00-P-0003-01A

1

Raise vehicle

2

Drain oil from rear axle differential (50)

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 rear wheel



Remove/install wheels, rotate if necessary

AP40.10-P-4050Z

4

Remove fixed brake caliper (111) from wheel carrier (7)

 Do not disconnect the brake hose. Tie up the fixed brake caliper (111) to the body.

Self-locking bolt, brake caliper to wheel carrier

*BA42.10-P-1001-12C

 Torque wrench

*001589662100

5

Remove stabilizer bar link rod (6k)

 Nut, link rod to stabilizer bar

*BA32.20-P-1001-04C

 Bolt, connecting rod to wheel carrier

*BA32.20-P-1005-04C

 Torque wrench

*001589662100

6

Remove left rear rpm sensor (L6/3) from wheel carrier (7).

 Self-locking bolt, rear axle rpm sensor to wheel carrier

*BA42.30-P-1001-02A

 Torque wrench

*000589672100

7

Remove torque strut (3) from wheel carrier (7)

 Installation: The rear axle shaft (37) must be horizontal (suspension compressed) when the torque strut (3) is tightened, to ensure that the axle geometry is not influenced.

 Self-locking nut, torque strut to wheel carrier

*BA35.20-P-1002-03A

 Torque wrench

*001589662100

8

Detach camber strut (2) from wheel carrier (7).

 Installation: The rear axle shaft (37) must be horizontal (suspension compressed) when the camber strut (2) is tightened, to ensure that the axle geometry is not influenced.

 Self-locking nut, camber strut to wheel carrier.

*BA35.20-P-1002-02A

 Torque wrench

*001589662100

9

Detach tie rod (4) from wheel carrier (7)

 Installation: The rear axle shaft (37) must be horizontal (suspension compressed) when the tie rod (4) is tightened, to ensure that the axle geometry is not influenced.

 Self-locking nut, tie rod to wheel carrier.

*BA35.20-P-1002-04A

 Puller

*201589013300

 Thrust piece M101.5

*210589046300

 Torque wrench

*001589662100

10

Remove thrust arm (5) from wheel carrier (7)

 Installation: The rear axle shaft (37) must be horizontal (suspension compressed) when the thrust arm (5) is tightened, to ensure that the axle geometry is not influenced.

 Self-locking nut, thrust arm to wheel carrier.

*BA35.20-P-1002-05A

 Torque wrench

*001589662100

11

Fold wheel carrier (7) outwards

 Do not over-stretch brake cable (arrow). Do not damage the rubber boots of the rear axle shaft (37) and the impulse ring for the left rear rpm sensor (L6/3) otherwise the electronic stability program (ESP) will not function correctly.

AR35.30-P-0620-02PA

 When doing so, pull the rear axle shaft (37) out of the rear axle differential.

 After pulling out, tie the wheel carrier (7) and rear axle shaft (37) to the body.

 Extraction and insertion tool

*210589034300

12

Press off radial sealing ring (32)

 Installation: Replace radial sealing ring (32) and coat the lip with universal hypoid gear oil.

AR35.31-P-0540-05CA



Universal hypoid gear oils (SAE 85 W-90)

Sheet 235.7

BB00.40-P-0235-07A

 Drift

*211589001500

13

Install new circlip (37o) on inner splined shaft of rear axle shaft (37)

14

Install in the reverse order



Checking

15

Check oil level in rear axle center assembly (50) 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

 For the rear axle differential 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 screw and oil drain screw changed on rear axle differential

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

16

Check rear axle differential (50) for leaks

 Carry out visual inspection.

Number

Designation

Model 203

Model 209

BA32.20-P-1001-04C

Nut, link rod to stabilizer bar

Nm

40

40

BA32.20-P-1005-04C

Bolt, link rod to wheel carrier

Nm

40

50

Number

Designation

Model
203

Model
209

BA35.20-P-1002-02A

Self-locking nut, camber strut to wheel carrier.

M10

Nm

-

-

M12

Nm

70

70

Number

Designation

Model
203

Model
209

BA35.20-P-1002-03A

Self-locking nut, torque strut to wheel carrier

M12

Nm

70

70

M16

Nm

-

-

Number

Designation

Model 203

Model 209

BA35.20-P-1002-04A

Self-locking nut, tie rod at wheel carrier

yellow M101

Nm

-

-

silver or blue M101

Nm

-

-

silver or blue M101.5

Stage 1

Nm

20

20

Stage 2

°

45

45

Number

Designation

Model
203

Model
209

BA35.20-P-1002-05A

Self-locking nut, thrust arm to wheel carrier

M10

Nm

-

-

M12

Stage 1

Nm

70

50

Stage 2

°

-

45

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

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
except
209.377/477,
except
model
209.376/476
as of 24.4.04

BA42.10-P-1001-12C

Self-locking bolt, brake caliper to wheel carrier

Nm

55

55

Number

Designation

Model 203

Model 209

BA42.30-P-1001-02A

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

Nm

8

8

Number

Designation

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

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

BF35.31-P-1001-01K

Filling capacity

Rear axle center assembly

Liters

0.95

1.1

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