Remove/install front axle shaft

AR33.30-S-6530EV

Remove/install front axle shaft

26.11.2019

Model

639.603/703 with engine 780.994

with code MA0 (E-CELL 60 kW)

Shown on left front axle shaft (1), vehicle with CODE RS3 (40.6 cm (16") steel wheels)

1

Front axle shaft

1.3

Constant velocity joint

4

Screws

1.1

Rubber boot (outboard)

2

Front axle shaft flange

5

Transmission

1.2

Rubber boot (at transmission end)

3

Collar nut

6

Hubcap (with CODE RS3 (40.6 cm (16") steel wheels))

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

Topical note

General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

AH00.00-Z-0300-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Remove

1

Raise vehicle with vehicle lift

AR00.60-S-1000S


Only raise vehicle far enough until the wheel bearing is relieved.
Otherwise damage could occur to the wheel bearing when the collar nut (3) is released.

2

Remove wheel trim (6)

Model 639.603 with engine 780.994
with code MA0 (E-CELL 60 kW)
with code RS3 (40.6 cm (16") steel wheels)

3

Release and unscrew collar nut (3) from front axle shaft (1)

AR33.30-S-6530-01EV


The vehicle may no longer be moved on its wheels when the collar nut (3) has been loosened.
Otherwise damage may occur to the wheel bearing.

 The front wheel must be on the ground when releasing the collar nut (3).

4

Release bolts (4) of front axle shaft (1) on transmission (5)

 When reinstalling the front axle shaft (1) to be removed, the installation position of the front axle shaft (1) must be marked on the transmission (5) before removal.

5

Remove front wheel

AR40.10-S-1100S

6

Detach supporting ball joint from steering knuckle

AR33.20-S-1452EV

7

Remove bolts (4) and detach front axle shaft (1) from transmission (5)

8.1

Pull front axle shaft (1) out of front axle shaft flange (2)

If the front axle shaft (1) is not firmly attached to the front axle shaft flange (2).


Do not pull front axle shaft (1) too far out of the constant velocity joint (1.3).
Otherwise the constant velocity joint (1.3) may be damaged.

8.2

Press front axle shaft (1) out of front axle shaft flange (2)

If the front axle shaft (1) is firmly attached to the front axle shaft flange (2).

AR33.30-S-0620-04EV


Do not knock seized front axle shaft (1) out of front axle shaft flange (2).
Otherwise the wheel bearing may be damaged.

 Extraction and insertion tool

*210589034300



Clean

9

Clean gearing (arrow) of front axle shaft (1) and gearing of front axle shaft flange (2)

10

Clean thread and contact surface for front axle shaft (1) on axle shaft flange of transmission (5)


The thread and contact surface on the axle shaft flange must be absolutely clean and free of grease.
Otherwise the threaded connection of the front axle shaft on the axle shaft flange (1) of the transmission (5) may work its way loose when the vehicle is being driven.

11

Clean contact surface on protective cap of transmission end of constant velocity joint on front axle shaft (1)


The contact surface on the protective cap must be absolutely clean and free of grease.
Otherwise the threaded connection of the front axle shaft on the axle shaft flange (1) of the transmission (5) may work its way loose when the vehicle is being driven.



Check

12

Check thread for mounting front axle shaft onto the transmission (5) axle shaft flange (1) for damage

If damage is present:



Replace axle shaft flange.

Remove/install axle shaft radial shaft sealing rings

AR26.40-S-0339EV

13

Check constant velocity joint (1.3) on front axle shaft (1) for damage

 Replace if front axle shaft (1) damaged.

14

Check rubber boot (1.1) on front axle shaft (1) for damage

If damage is present:



Replace rubber boot (1.1).

Remove/install rubber boot at outboard end of front axle shaft

AR33.30-S-7619EV

15

Check rubber boot (1.2) on front axle shaft (1) for damage

If damage is present:



Replace rubber boot (1.2).

Remove/install rubber boot at transmission end of front axle shaft

AR33.30-S-7620EV



Install

16

Apply light coating of grease to gearing (arrow) of front axle shaft (1)

Long-life grease

*BR00.45-Z-1001-06A

17

Install front axle shaft (1) into front axle shaft flange (2)

18

Screw collar nut (3) onto front axle shaft (1) up to attachment

 Use a new collar nut (3).

19

Mount front axle shaft (1) to transmission (5) and screw in bolts (4) finger-tight

 Use new screws (4).
Apply light coating of thread locking agent to thread of bolts (4).

 When reinstalling previously removed front axle shaft (1), observe the markings for the installation position on the transmission (5).

Loctite 262

*BR00.45-Z-1059-02A

20

Mount supporting ball joint onto steering knuckle

AR33.20-S-1452EV

21

Mount front wheel

AR40.10-S-1100S

 Screw wheel bolts finger-tight only. Tighten wheel bolts only after the bolts (4) have been tightened.

22

Tighten bolts (4) of front axle shaft (1) on transmission (5)

 An assistant is required to counterhold the front wheel.

 Procedure when tightening bolts (4):

1.: Tighten bolts (4) crosswise with 1st stage initial torque.
2.:Tighten bolts (4) crosswise with 2nd stage initial torque, then release bolts (4) individually.
3.: Tighten bolts (4) with 3rd stage initial torque.
4.: Tighten bolts (4) with 4th stage additional tightening angle.

 Bolt, front axle shaft to transmission

*BA33.30-N-1003-02A

23

Tighten wheel bolts on front wheel

AR40.10-S-1100S

24

Tighten and secure collar nut (3) on front axle shaft (1)

AR33.30-S-6530-01EV


The wheel bearing must be relieved.
Otherwise damage may occur to the wheel bearing.


The collar nut (3) must be properly secured.
Otherwise the collar nut (3) may work its way loose.

 The front wheel must be on the ground when collar nuts (3) are tightened.

 Collar nut, front axle shaft to wheel bearing

*BA33.30-N-1001-02A

25

Mount wheel trim (6)

Model 639.603 with engine 780.994
with code MA0 (E-CELL 60 kW)
with code RS3 (40.6 cm (16") steel wheels)

 Front axle shaft

Number

Designation

MODEL 639.603/703 with CODE MA0

BA33.30-N-1001-02A

Collar nut, front axle shaft to wheel bearing

Stage 1

Nm

125

Stage 2

°

60

 Front axle shaft

Number

Designation

MODEL 639.603/703 with CODE MA0

BA33.30-N-1003-02A

Bolt, front axle shaft to transmission

Stage 1

Nm

30

Stage 2

Nm

65

Stage 3

Nm

30

Stage 4

°

120

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11

BR00.45-Z-1059-02A

Loctite 262

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