AR35.31-P-0550D | Disassembling and assembling rear axle differential, adjusting gear set | 16.10.09 |
Rear axle differential dia. 210
in MODEL 124.008 /028 /029 /031 /032 /034 /036 /051 /052 /061 /066 /088 /091 /092,
129.058 up to 31.5.94,
129.061,
129.063 up to 31.5.94,
129.066,
140.028 /032 /033 up to 31.5.94,
140.042 /043 /063 /1,
210.070 up to 31.1.98,
210.072,
210.074 /270 up to 31.1.98,
210.272,
210.274 up to 31.1.98,
210.617
P35.31-0431-09
11a Tapered roller bearing outer race
11b Tapered roller bearing inner race
13 Differential
13a Retaining bolts
25 O-ring
26 Shim
27a Hexagon bolt
27b Side bearing cap (standard)
27c Side bearing cap (ASR)
27d Side bearing cap (ASD)
30 Retaining ring
31b Spacer ring
32 Radial sealing ring (standard)
32a Radial sealing ring (ASR)
33 Connecting flange (standard)
47a Ring gear
48 Bearing washers
49 ABS gear
50 Rear axle center assembly
54 End cover
55 Rear axle breather
56 Screw
56b Collar bolt
70j Radial sealing ring (ASD)
70l Hydraulic line
A Standard version
B ASR version
C ASD version
33a Connecting flange (ASR)
33b Connecting flange (ASD)
40 Twelve-point collar nut
41 Joint flange, 3 arm
41a Joint flange, 4 arm
42 Radial sealing ring
43a Thrust washer
43d Tapered roller bearing inner race
43e Tapered roller bearing outer race
44 Spacer sleeve
45 Shim
46a Tapered roller bearing inner race
46b Tapered roller bearing outer race
47 Drive pinion
| Removing | ||
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. | |
1 | Raise vehicle with vehicle lift | ||
2 | Drain oil from rear axle differential (50) | ||
Cleaning spray, Loctite 7063 (150ml) | |||
Sealant, Omnifit 100H (50 g) | |||
Oil drain screw | |||
| Oil filler/drain screw on rear axle differential modified | Phased in as of 19.01.04 | |
3 | Remove rear axle differential (50) | Model 124 | |
Model 129 | |||
Model 140 | |||
Model 210 | |||
| Tapped hole for rpm sensor relocated at rear axle housing | Model 124, 129, 140 | |
| Features, installation survey for rear axle differentials | ||
| Disassemble | ||
4 | Clamp rear axle differential (50) in assembly stand. | | |
5 | Remove end cover (54) | ||
6 | Pull retaining rings (30) off both connecting flanges (33 or 33a, 33b). | | |
7 | Pull out connecting flanges (33 or 33a, 33b). | ||
8.1 | Detach grooved ball bearing of connecting flange | Vehicles with rear axle with automatic locking differential (ASD) code 211a or with acceleration skid control (ASR) code 471a | |
9.1 | Remove spacer rings (31b) | Vehicles without ASD | |
10.1 | Remove hydraulic line (70l). | Vehicles with rear axle with automatic locking differential (ASD) code 211a | |
11 | Detach side bearing caps (27b or 27c, 27d) | Mark bearing cap and shim (26). | |
12 | Take differential (13) out of rear axle housing | ||
13 | Knock left and right radial sealing ring (32 or 32a, 70j) out of bearing caps | ||
14 | Press both tapered roller bearing outer races (11a) out of bearing caps | Mark tapered roller bearing outer races (11a) | |
Vehicles without ASD | |||
Vehicles with rear axle with automatic locking differential (ASD) code 211a | |||
15 | Detach both tapered roller bearing inner races (11b) from differential (13) | Mark tapered roller bearing inner races (11b). | |
16 | Loosen and remove retaining bolts (13a) from crown wheel (47a) | Mark position of ring gear (47a) in relation to differential (13). | |
17 | Carefully press off crown wheel (47a) from differential (13) | ||
18 | Loosen and remove twelve-point collar nut (40) from joint flange (41 or 41a). | | |
19 | Pull off joint flange (41 or 41a) | If necessary, mark joint flange with respect to drive pinion. | |
| Radial sealing ring and joint flange on drive pinion modified | As of 01.04.98 | |
20 | Push drive pinion (47) out of rear axle housing | | |
21 | Press radial sealing ring (42) out of the rear axle housing using a suitable screwdriver. | ||
| Radial sealing ring and joint flange on drive pinion modified | As of 01.04.98 | |
22 | Remove tapered roller bearing inner race (43d) with thrust washer (43a). | ||
| Integrated thrust washer on tapered roller bearing inner race | As of 14.02.94 | |
23 | Remove tapered roller bearing outer races (46b, 43e) and shim (45) from rear axle housing. | | |
24 | Remove spacer sleeve (44) with thrust plates (48) from drive pinion (47) | ||
25.1 | Pull ABS gear (49) off drive pinion (47). | Vehicles with antilock brake system (ABS) code 470a, except vehicles with ETS, ASR, ESP | |
26 | Pull tapered roller bearing inner race (46a) from drive pinion (47) | | |
| Checking | ||
27 | Inspect all parts to determine whether they can be reused, replace if necessary | If the contact surfaces of the connecting and joint flanges show signs of severe galling due to the radial sealing ring, the flanges must be replaced with new flanges. | |
28.1 | Check drive pinion (47) and ring gear (47a) for match-up number | Only lapped gear sets up to approx. 06/95 have a match-up number. | |
Each lapped gear set is checked for the best possible smooth running and marked with a consecutive match-up number that is marked on both parts. | |||
| Ground ring gear and pinions | Phased in as of 06/95 | |
| Assembly, adjusting ring gear and pinion | ||
29 | Press tapered roller bearing inner race (46a) onto drive pinion (47) | ||
| Press-on sleeve for tapered roller bearing inner race | ||
30.1 | Press ABS gear (49) onto drive pinion (47). | Vehicles with antilock brake system (ABS) code 470a, except vehicles with ETS, ASR, ESP | |
| Press-on sleeve for ABS gear | ||
Number of teeth on ABS gear: | |||
| Features, installation survey for rear axle differentials | ||
31 | Calculate shim (45) and installing in rear axle housing | Use data sheet: | |
Data sheet, Adjusting rear axle gear set: Order No. B20.650.06.080.00B | |||
32 | Pull tapered roller bearing outer races (43e, 46b) into rear axle housing | | |
33 | Install spacer sleeve (44) on drive pinion (47) with double-sided thrust plates (48) | Always replace spacer sleeve (44) and thrust plates (48). | |
34 | Insert drive pinion (47) into rear axle housing. | Support drive pinion (47) with removal and installation tool. | |
35.1 | Clip pressure plate (43a) onto tapered roller bearing inner race (43d). | Rear axle differentials up to 13.02.94 | |
| Integrated thrust washer on tapered roller bearing inner race | Rear axle differentials as of 14.02.94 | |
36 | Install tapered roller bearing inner race (43d) on drive pinion (47) and press in together with radial sealing ring (42). | Replace radial sealing ring (42) and coat the lip with universal hypoid gear oil. | |
| Universal hypoid gear oil | ||
| Radial sealing ring and joint flange on drive pinion modified | As of 01.04.98 | |
37 | Slide joint flange (41 or 41a) onto drive pinion (47) | Possibly observe applied marking. Coat contact face for radial sealing ring with universal hypoid gear oil. | |
| Universal hypoid gear oil | ||
| Imbalance on drive pinion joint flange reduced | Model 124, 129 | |
| Radial sealing ring and joint flange on drive pinion modified | As of 01.04.98 | |
38 | Screw on twelve-point collar nut (40). | Replace twelve-point collar nut. | |
Socket | |||
39 | Adjusting friction torque of drive pinion bearing | | |
40 | Check adjustment dimension for drive pinion (47) | | |
41 | Secure twelve-point collar nut (40) on joint flange (41 or 41a). | ||
| Caulker for securing twelve-point collar nut (40) on joint flange (41 or 41a) | ||
42.1 | Dismantling and assembling differential (13) | Vehicles without ASD | |
42.2 | Disassemble/assemble ASD differential (13). | Vehicles with rear axle with automatic locking differential (ASD) code 211a | |
43 | Mount ring gear (47a) onto differential (13) | Observe marking applied to ring gear (47a) and differential (13). | |
44 | Press tapered roller bearing inner races (11b) onto differential (13) | | |
45 | Press both tapered roller bearing outer races (11a) into bearing cap | Vehicles without ASD | |
Vehicles with rear axle with automatic locking differential (ASD) code 211a | |||
46 | Press radial sealing rings (32 or 32a, 70j) into bearing cap. | Replace radial sealing ring (32 or 32a, 70j) and coat the sealing lip with Universal hypoid gear oil. | |
| Universal hypoid gear oil | ||
Vehicles without ASD/ASR | |||
Vehicles with acceleration skid control (ASR) code 471a | |||
Vehicles with rear axle with automatic locking differential (ASD) code 211a | |||
47 | Slide side bearing cap (27b or 27c, 27d) into rear axle housing (50) and insert differential (13) | Observe mark placed on bearing cap with shim (26). Coat circumference of O-rings in bearing cap with Universal hypoid gear oil. | |
| Universal hypoid gear oil | ||
48 | Pre-tension (spread) rear axle housing and measure spread dimension (expansion) | | |
49 | Measure gear backlash between drive pinion (47) and ring gear (47a), correct if necessary. | The adjustment of the tapered roller bearing and the gear set are OK, when the spreading dimension (widening) of the rear axle housings and the gear backlash are within the nominal values. This prevents damage to the teeth of the drive pinion gear (47) and the ring gear (47a). | |
50 | Detach end stops for measuring bracket | ||
51.1 | Press on grooved ball bearing of connecting flange | Vehicles with rear axle with automatic locking differential (ASD) code 211a or with acceleration skid control (ASR) code 471a | |
52.1 | Attach hydraulic line (70l). | Vehicles with rear axle with automatic locking differential (ASD) code 211a | |
53.1 | Slide spacer rings (31b) onto connecting flanges (33 or 33a). | Vehicles without ASD | |
54 | Install connecting flanges (33 or 33a, 33b) in differential (13). | ||
| Connecting flange with centering | Model 124, 129, 140 | |
55 | Place retaining rings (30) onto connecting flanges (33 or 33a, 33b) | Replace retaining ring (30). | |
56.1 | Check axial play of connecting flange (33 or 33a), adjust if necessary | Vehicles without ASD | |
Adjustment of the axial play is not required for vehicles with rear axle with automatic locking differential (ASD) code 211a | |||
57 | Attach end cover (54) | Clean sealing surface and coat with sealant. | |
58 | Replace rear axle breather (55) on rear axle housing | | |
59 | Remove rear axle differential (50) from assembly stand | ||
| Install | ||
60 | Install rear axle differential (50). | Model 124 | |
Model 129 | |||
Model 140 | |||
Model 210 | |||
| Tapped hole for rpm sensor relocated at rear axle housing | Model 124, 129, 140 | |
61 | Pour oil into the rear axle differential (50) | Model 129, 140, 210 | |
129 | |||
140 | |||
210 | |||
Cleaning spray, Loctite 7063 (150ml) | |||
Sealant, Omnifit 100H (50 g) | |||
Oil filler screw for rear axle differential | |||
Model 124 | |||
124 | |||
Cleaning spray, Loctite 7063 (150ml) | |||
Sealant, Omnifit 100H (50 g) | |||
Oil filler screw for rear axle differential | |||
| Oil filler/drain screw on rear axle differential modified | Phased in as of 19.01.04 | |
62.1 | Bleed ASD hydraulic system | Vehicles with rear axle with automatic locking differential (ASD) code 211a | |
Model 124 | |||
Model 129 | |||
Model 140 |
Test values for friction torque of rear axle differential
Number | Designation | Model 124.008/028/029/ | Models 129.058/063 up to 31.05.94 | |
BE35.31-P-1001-02D | Friction torque of drive pinion bearing | Ncm | 125 to 150 | 125 to 150 |
Test values for friction torque of rear axle differential
Number | Designation | Models 140.028/032/ | Models 210.070/ | |
BE35.31-P-1001-02D | Friction torque of drive pinion bearing | Ncm | 125 to 150 | 125 to 150 |
Test values for rear axle differential
Number | Designation | Model 124 | Model 129 | |
BE35.31-P-1001-03A | Permissible deviation from the specified adjustment dimension on the end face of the drive pinion | mm | -0.02/+0.01 | -0.02/+0.01 |
BE35.31-P-1002-03A | Gear backlash between crown wheel and pinion | mm | 0,08-0,14 | 0,08-0,14 |
BE35.31-P-1003-03A | Crown wheel heating temperature for installation | °C | 75-85 | 75-85 |
Test values for rear axle differential
Number | Designation | Model 140 | Model 210 | |
BE35.31-P-1001-03A | Permissible deviation from the specified adjustment dimension on the end face of the drive pinion | mm | -0.02/+0.01 | -0.02/+0.01 |
BE35.31-P-1002-03A | Gear backlash between crown wheel and pinion | mm | 0,08-0,14 | 0,08-0,14 |
BE35.31-P-1003-03A | Crown wheel heating temperature for installation | °C | 75-85 | 75-85 |
Test values for rear axle housing expansion
Number | Designation | Model 124.008/028/029/ | Models 129.058/063 up to 31.05.94 | |
BE35.31-P-1001-04D | Setting for rear axle housing expansion (spread dimension) | mm | 0,15-0,20 | 0,15-0,20 |
Test specifications for rear axle housing expansion
Number | Designation | Models 140.028/032/ | Model 210.070/ | |
BE35.31-P-1001-04D | Setting for rear axle housing expansion (spread dimension) | mm | 0,15-0,20 | 0,15-0,20 |
Test values for connecting flange/differential housing
Number | Designation | Type 124 | Model 129 | Type 140 | Model 210 | |
BE35.31-P-1001-05A | Axial play between connecting flange and differential housing | mm | 0.03 to 0.3 | 0.03 to 0.3 | 0.03 to 0.3 | 0.03 to 0.3 |
Rear axle center assembly housing
Number | Designation | Model | Model | |||
BA35.31-P-1001-02A | Bolt, end cover to rear axle differential | Bolt+washer | Nm | 50 | 50 | |
Flange bolt | Stage 1 | Nm | 30 | 30 | ||
Stage 2 | ° | 45 | 45 | |||
BA35.31-P-1002-02A | Oil filler screw, rear axle 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 | 30 | ||
BA35.31-P-1006-02A | Bolt of side bearing cap to rear axle center assembly | Nm | 20 | 20 | ||
Rear axle center assembly housing
Number | Designation | Type | Model | |||
BA35.31-P-1001-02A | Bolt, end cover to rear axle differential | Bolt+washer | Nm | 50 | - | |
Flange bolt | Stage 1 | Nm | 30 | 30 | ||
Stage 2 | ° | 45 | 45 | |||
BA35.31-P-1002-02A | Oil filler screw, rear axle 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 | 30 | 25 | ||
BA35.31-P-1006-02A | Bolt of side bearing cap to rear axle center assembly | Nm | 20 | - | ||
Rear axle differential gear set
Number | Designation | Model 124.008/028/029/ | Models 129.058/063 up to 31.05.94 | ||
BA35.31-P-1001-03D | Retaining bolt, ring gear to differential case | Without ratchet teeth | Nm | 120 | 120 |
With ratchet teeth | Nm | 140 | 140 | ||
Rear axle differential gear set
Number | Designation | Models 140.028/032/ | Model 210.070/074/ | ||
BA35.31-P-1001-03D | Retaining bolt, ring gear to differential case | Without ratchet teeth | Nm | 120 | 120 |
With ratchet teeth | Nm | 140 | 140 | ||
Rear axle differential
Number | Designation | Model Series 140.02/03 | Model Series 140.02/03 | Model Series 140.04/06 | ||
BF35.31-P-1001-01A | Filling capacity | Rear axle center assembly | Liters | 1,3 | 1,3 | 1,3 |
Specifications for Operating Fluids | Sheet | | ||||
Sheet | ||||||
Rear axle differential
Number | Designation | Model Series 140.1 without (Code 211) ASD | Model Series 140.1 with (Code 211) ASD | ||
BF35.31-P-1001-01A | Filling capacity | Rear axle center assembly | Liters | 1,3 | 1,3 |
Specifications for Operating Fluids | Sheet | | |||
Sheet | |||||
Rear axle differential
Number | Designation | Model 124.008/028/029/ | Model 124.008/028/029/ | ||
BF35.31-P-1001-01B | Filling capacity | Rear axle center assembly | Liters | 1,3 | 1,3 |
Specifications for Operating Fluids | Sheet | ||||
Sheet | - | ||||
Rear axle differential
Number | Designation | Models 129.058/063 without (Code 211) ASD up to 05/94 | Models 129.058/061/ | ||
BF35.31-P-1001-01C | Filling capacity | Rear axle center assembly | Liters | 1,3 | 1,3 |
Specifications for Operating Fluids | Sheet | | |||
Sheet | |||||
Rear axle differential
Number | Designation | Type 129.066 | Model 129.061 | ||
BF35.31-P-1001-01C | Filling capacity | Rear axle center assembly | Liters | 1,3 | 1,3 |
Specifications for Operating Fluids | Sheet | ||||
Sheet | |||||
Rear axle differential
Number | Designation | Models 210.070/ | ||
BF35.31-P-1001-01E | Filling capacity | Rear axle center assembly | Liters | 1,3 |
Specifications for Operating Fluids | Sheet | |||
129 589 02 43 00
116 589 00 35 00
129 589 00 31 00
116 589 01 62 00
Removal and installation tool
Removal and installation tool
Assembly stand
Remover
126 589 02 09 00
129 589 01 33 00
123 589 08 33 00
129 589 01 07 00
Wrench socket
Pin wrench
Puller
Puller
001 589 50 33 00
000 589 63 34 00
201 589 02 43 00
000 589 88 33 00
Puller
Two-armed puller
Removal and installation tool
Extension
363 589 02 21 00
601 589 00 23 00
000 589 34 34 00
140 589 00 01 00
Dial indicator holder
Open end wrench
Chuck
Measuring plate
111 589 08 23 00
115 589 05 21 00
116 589 07 21 00
116 589 01 21 00
Dial indicator holder
Measuring device
Measuring device
Adjustment gauge
124 589 02 15 00
208 589 00 15 00
116 589 11 61 00
000 589 65 33 00
Drift
Puller
Installer
Drift
100 589 02 59 00
Remote thermometer
Connecting piece
Torque meter
Drift
001 589 49 21 00
124 589 07 21 00
140 589 06 15 00
124 589 01 15 00
Spring compressor
Drift
Drift
Spring compressor
126 589 04 15 00
116 589 08 61 00
116 589 18 61 00
126 589 08 21 00
Tooth backlash gauge
Contact arm
Stop
Chuck
201 589 01 63 00
201 589 03 21 00
140 589 00 34 00
Repair materials
Number | Designation | Order number |
BR00.45-Z-1010-01A | Sealing compound, Hylomar universal sealant, 80 ml | A 001 989 25 20 |
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 |
Referenced documents
- ar3531p052003a Check rear axle center assembly oil level, top up if necessary
- ar3531p052003aa Check rear axle center assembly oil level, top up if necessary
- ar3531p052006a Drain oil from rear axle center assembly
- ar3531p0520a Remove/install differential
- ar3531p0520b Remove/install differential
- ar3531p0520c Remove/install differential
- ar3531p053001b Secure twelve-point and hexagon collar nut on drive pinion joint flange
- ar3531p054001a Detaching, mounting connecting flange circlip
- ar3531p054002a Check and adjust axial play of connecting flange
- ar3531p054004a Pulling off and pressing on grooved ball bearing connecting flange
- ar3531p054006b Clamp rear axle center assembly in assembly frame
- ar3531p055004c Pulling tapered roller bearing inner races off differential
- ar3531p055006b Pulling off joint flange
- ar3531p055007a Pressing drive pinion out of rear axle housing
- ar3531p055008b Pressing radial sealing ring out of rear axle housing
- ar3531p055009d Removing tapered roller bearing outer races from rear axle housing
- ar3531p055010c Removing tapered roller bearing inner race from drive pinion
- ar3531p055011a Checking drive pinion and crown wheel for pairing number
- ar3531p055012c Pressing tapered roller bearing inner race onto drive pinion
- ar3531p055013d Calculating shim and installing in rear axle housing
- ar3531p055014c Pull tapered roller bearing outer races into rear axle housing
- ar3531p055015d Installing drive pinion in rear axle housing
- ar3531p055016c Installing tapered roller bearing inner race on drive pinion and pressing in together with radial sealing ring
- ar3531p055017c Adjusting friction torque of drive pinion bearing
- ar3531p055018d Checking adjustment dimension of drive pinion
- ar3531p055019d Fitting ring gear on differential
- ar3531p055020d Pressing tapered roller bearing inner races onto differential
- ar3531p055025d Measuring gear backlash between drive pinion and crown wheel and correcting if necessary
- ar3531p055026b Fitting spacer sleeve with bearing washers on both sides onto drive pinion
- ar3531p055028d Attaching end cover
- ar3531p055030b Removing ABS gear from drive pinion
- ar3531p055031b Pressing ABS gear onto drive pinion
- ar3531p055035c Unfasten, remove twelve-point collar nut on joint flange
- ar3531p055037c Clipping thrust washer onto tapered roller bearing inner race
- ar3531p055039d Detaching side bearing covers
- ar3531p055040d Knocking radial seal ring out of bearing cover
- ar3531p055041d Pressing tapered roller bearing outer races out of and into bearing cover
- ar3531p055041e Pressing tapered roller bearing outer races in and out of bearing cover
- ar3531p055042d Pressing radial seal ring into bearing cover
- ar3531p055042e Pressing radial seal ring into bearing cover
- ar3531p055042f Pressing radial seal ring into bearing cover
- ar3531p055043d Pushing side bearing covers into rear axle housing and installing differential gear
- ar3531p055044d Pre-tension (spreading) rear axle housing and measuring expanded dimension (expansion)
- ar3531p0560a Disassembling and assembling differential
- ar3541p0519a Bleeding ASD hydraulic system
- ar3541p0519c Bleeding ASD hydraulic system
- ar3541p054501d Detaching and attaching ASD hydraulic pipe on rear axle center assembly
- ar3541p0560c Dismantling and assembling ASD differential
- as0000z001001a Risk of death caused by vehicle slipping or toppling off of the lifting platform.
- bb0040p023507a Universal hypoid gear oils (specification 235.7)
- bt3531p000401a Tapped hole of speed sensor on rear axle housing moved
- bt3531p000701a Imbalance on joint flange drive pinion reduced
- bt3531p000901a Connecting flange with centering
- bt3531p001101b Gear sets ground
- bt3531p001201a Radial sealing ring and joint flange on drive pinion modified
- bt3531p001501a Oil filler screw and oil drain screw changed on rear axle center assembly
- bt3531p940201a Integrated thrust washer on tapered roller bearing inner race
- gf3531p100001d Features, installation survey for rear axle center assemblies
- ra35001240519x 0519 - Bleeding the ASD hydraulic system Models 124, 201
- ra35001240520x 0520 - Removal and installation of the rear axle center assembly A. Model 124, B. Model 201
- wf5850p353101a Chisel for securing collar nut on joint flange
- wf5850p353103b Press on sleeve for tapered roller bearing cone on drive pinion
- wf5850p353104b Produce press-on sleeve for ABS gear on drive pinion in accordance with drawing.