Remove/install differential

AR35.31-P-0520D

Remove/install differential

30.8.10

20.3.04

Oil filler/drain screw on rear axle differential modified

Phased in as of 19.01.04

 The oil filler screws and oil drain screws should always be replaced after being unscrewed.

The new oil filler screws and drain screws as well as the tapped holes must be cleaned with a special cleaning spray and provided with a special sealing compound.

BT35.31-P-0015-01A

The oil filler screw should always be replaced after being unscrewed from the rear axle differential.

The new oil filler screw as well as the tapped hole must be cleaned with a special cleaning spray and the oil filler screw provided with a special sealing compound

 Only carry out oil level check at interior temperature.

AR35.31-P-0520-03A

 

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



Features, installation survey for rear axle differentials

Rear axle differential with crown wheel dia. 168 mm

GF35.31-P-1000-01B



Features, installation survey for rear axle differentials

Rear axle differential with crown wheel dia. 185 mm

GF35.31-P-1000-01C



Features, installation survey for rear axle differentials

Rear axle differential with crown wheel dia. 198 mm

GF35.31-P-1000-01A



Features, installation survey for rear axle differentials

Rear axle differential with 210 mm crown wheel dia. in rear axle differential 210E

GF35.31-P-1000-01I

1

Raise vehicle with vehicle lift

2.1

Detach hydraulic line (HS)

Model 202 with ASD up to 05/94

 Seal thread opening on ring cylinder and hydraulic line (HS).

3.1

Remove rear axle rpm sensor (L6)

If installed.

ra42001240714x

 Installation: Clean magnetic blade and replace O-ring.

4.1

Remove rear left and right rpm sensor (L6/3, L6/4)

Model 202 with ASR up to 05/94

ra42002020820x

5

Remove exhaust system (105) from flange connection

See: 

Remove exhaust system (105) completely

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 with engine 112.910/920, 113.944
Model 208 with engine 112.940, 113.943/984

AR49.10-P-7000AU

Model 208 with engine 111.945/975

AR49.10-P-7000DA

6

Remove exhaust heat shield (105c)

7.1

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: Changed over to sliding piece connection.

BT41.10-P-9110-01DA

8

Detach propeller shaft intermediate bearing (106a)

 Installation: Only tighten the bolts of the propeller shaft intermediate bearing (106a) after fixing the flexible coupling to the rear axle differential (50).



*BA41.40-P-1001-01A

9

Detach the rear propeller shaft (106) from the rear axle differential (50)

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

With firmly attached fitted sleeves: 

Loosen fitting sleeves on flexible couplings.

AR41.10-P-0050-09DA



Drift for loosening fitting sleeves in flex disks.

WF58.50-P-4110-01A

 Place rear propeller shaft (106) on the reinforcement bracket.



*BA41.10-P-1002-01A

10.1

Detach cover (140) of fuel pump assembly and unhook fuel pump assembly from the rubber rings

Vehicles with gasoline engine

11

Detach rear axle shafts (37) from the connecting flanges

 Move the rear axle shaft (37) into approximately the horizontal position and push together. Tie the rear axle shafts (37) securely to the rear axle carrier.

 Installation: Replace self-locking multipoint, hexagon socket or Torx bolts and washers.

Lightly oil bolts at thread and bolt head contact surface.



*BA35.30-P-1002-01A

12

Support rear axle differential (50)

 Assembly attachment

*140589016200

13

Remove bolts (50a) and remove stop plate (50b)

AR35.31-P-0520-02A



*BA35.10-P-1004-01A

14

Remove front differential mounting

 Installation: Attach front differential mounting

AR35.10-P-0050-01A



*BA35.10-P-1003-01A



Front suspension on rear axle differential modified

Model 202.018/022/028/120/121/125
as of 07/93

BT35.31-P-0001-01B

15

Lower and remove rear axle differential (50)

16

Replace rear axle differential breather



*BA35.31-P-1005-02A

17

Install in the reverse order

18.1

Bleed ASD hydraulic system

Model 202 with ASD up to 05/94

AR35.41-P-0519C

19

Check oil level in rear axle differential and correct if necessary

 Mixing old Universal hypoid gear oil and the FE-hypoid gear oil should be avoided for better fuel economy.

AR35.31-P-0520-03A

 Model 170

*BF35.31-P-1001-01F

Model 202

*BF35.31-P-1001-01D

Model 208

*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

BA35.10-P-1003-01A

Self-locking nut, rear axle differential at front to rear axle carrier

Nm

50

50

50

BA35.10-P-1004-01A

Self-locking bolt, rear axle differential at rear to rear axle carrier

Nm

110

110

110

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

Model
202

BA35.31-P-1002-02A

Oil filler screw, 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-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