Remove/install axle drive module of front axle with tubular frame

AR08.10-D-0008TE

Remove/install axle drive module of front axle with tubular frame

21.11.2019

Engine

780.703 in model 910

Modification notes

21.11.2019

Method modified.

Operation step 55

21.11.2019

Basic data reference altered.

Operation step 37

1

Axle drive module

29

Coolant hose

33

High-voltage lines

2

Electrical line

30

Coolant hose

34

High-voltage connection

3

Electrical line

31

Ground cable

35

High-voltage connection

4

Electrical connector

32

Cover

36

High-voltage connection

28

Coolant hose

5

Nut

9

High-voltage lines

13

Electrical wiring harness

6

Refrigerant line

10

Cover

14

Electrical connector

7

Refrigerant line

11

Electrical connector

17

Vacuum line

8

Refrigerant line

12

Ground cable

27

Coolant hoses

15

High-voltage connection

20

Ground cable

24

Coolant line

16

High-voltage connection

21

Ground cable

25

Coolant line

18

Electrical connector

22

Electrical connectors

26

Coolant hose line

19

Electrical wiring harness

23

Coolant line

1

Axle drive module

39

Coolant line

42

Coolant line

37

Coolant line

40

Electrical connector

43

Bolts

38

Coolant line

41

Coolant line

44

Bolts

1

Axle drive module

45

Lifting platform

 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

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Warning

Risk of poisoning caused by inhaling overheated refrigerant vapors from an air conditioning system containing R134a. Risk of injury to skin and eyes caused by contact with liquid R134a refrigerant and when working on pressurized parts

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0006-01A

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

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

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Topical note

Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A

Notes on handling refrigerant R134a

AH83.30-N-0003-01A

 

Remove/install

1

Drain refrigerant circuit.

AR83.30-D-1760TS

2

Drain coolant of main circuit.

AR08.50-D-0023TE

3

Drain coolant of auxiliary circuit.

AR08.50-D-0022TE

4

Remove voltage of high-voltage on-board electrical system.

AR47.70-D-1000TE

5

Detach ground line of on-board electrical system battery.

AR54.10-D-0029TS

6

Make electric lines (2, 3) accessible.

AR54.10-D-0009TSF

 For this purpose, remove floor covering and battery cover. Do not remove on-board electrical system battery.

7

Remove electric lines (2, 3).

 For this purpose, remove nuts.

 Installation: Observe torque data on prefuse box housing.

8

Disconnect electrical connection (4).

9

Remove nut (5).


Counterhold refrigerant line (6) when releasing and tightening nut (5) in area of line flange with a suitable tool.
Refrigerant lines (6, 7, 8) can otherwise be damaged.

 Nut, refrigerant line to refrigerant line

*BA83.30-N-1009-01TS

10

Remove refrigerant lines (7, 8) from refrigerant line (6).



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Seal openings at refrigerant lines (6, 7, 8).

 Installation: Replace sealing rings and coat with compressor oil.

 Record plug

*129589009100

11

Remove ventilation box.

AR83.10-D-0010TS

12

Remove high-voltage lines (9) from cover (10).

 Installation: Check retaining clips for damage.

If damage is present:



Replace damaged retaining clips.

13

Separate electrical connector (11).

14

Disconnect ground line (12) from DC current charge-connection unit.

Check ground lines for high-voltage on-board electrical system potential equalization

AR47.70-D-1020-01TE

 Installation: Check ground line (12).

 Screw, potential equalization ground line/protective ground conductor to DC current charge-connection unit

*BA47.70-N-1009-02TE

15

Remove ground line (12) and electrical wiring harness (13) from cover (10).

 Installation: Check retaining clips for damage.

If damage is present:



Replace damaged retaining clips.

16

Disconnect electrical connector (14).

17

Release and disconnect high-voltage plug (15).

18

Release and disconnect high-voltage plug (16).

19

Place high-voltage lines (9), ground line (12) and electrical wiring harness (13) toward front outside of working area.

20

Cover high-voltage connections with suitable protective covers.

 Set of protective covers

*001589019100

21

Remove vacuum line (17) at brake booster.

AR43.10-D-0355TE

 Vacuum line (17) remains at brackets and at vacuum pump.

22

Disconnect electrical connector (18).

23

Remove electrical wiring harness (19) at tubular frame.

 Installation: Check retaining clips for damage.

If damage is present:



Replace damaged retaining clip.

24

Remove ground lines (20, 21) at right front longitudinal member.

Check ground lines for high-voltage on-board electrical system potential equalization

AR47.70-D-1020-01TE

 Installation: Check ground lines (20, 21).

 Nut, potential equalization ground line to body

*BA47.70-N-1006-02TE

 Screw, potential equalization ground line to DC/DC converter

*BA47.70-N-1007-02TE

 Nut, potential equalization ground line to high-voltage components holder in engine compartment

*BA47.70-N-1008-02TE

25

Remove electrical connectors (22).

 For this purpose, open cable ties.

 Installation: Replace cable tie.

26

Disconnect electrical connectors (22).

27

Remove coolant lines (23, 24) at expansion reservoir auxiliary circuit.

AR08.50-P-0018-01EQ

 Seal connections. Collect escaping coolant.

 Commercially available devices/tools
Collecting pan

 Set of protective caps

*001589009100

 Record plug

*129589009100

28

Remove coolant line (25) at coolant radiator main circuit.

AR08.50-P-0018-01EQ

 Seal connections. Collect escaping coolant.

 Commercially available devices/tools
Collecting pan

 Set of protective caps

*001589009100

 Record plug

*129589009100

29

Remove coolant hose line (26) of expansion reservoir main circuit at coolant radiator main circuit.

AR08.50-P-0018-01EQ

 Seal connections. Collect escaping coolant.

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

30

Remove coolant hoses (27) from heater housing.

 Seal connections. Collect escaping coolant.

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

 Hose clamp pliers

*454589003700

31

Raise vehicle.

32

Secure vehicle on vehicle lift.

AR00.60-D-0100-01TS

 Commercially available devices/tools
Tensioning strap

33

Remove integral carrier.

AR31.35-D-0001TE

34

Remove left front axle shaft from axle drive module (1).

AR33.30-D-0621TE

 Secure left front axle shaft at underbody.

35

Remove right front axle shaft from axle drive module (1).

AR33.30-D-0622TE

 Secure right front axle shaft at underbody.

36

Disconnect coolant hoses (28, 29, 30).

AR08.50-P-0018-01EQ

 Seal connections. Collect escaping coolant.

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

37

Remove ground line (31).

 Nut, ground line to body

*BA54.10-N-1003-01TS

38

Remove cover (32) at battery box and implement electric lines (2, 3) downwards.

 Long wedge

*115589035900

39

Remove high voltage lines (33) at battery box and at bracket of underbody high-voltage power distributor.

 Installation: Check retaining clips for damage.

If damage is present:



Replace damaged retaining clips.

40

Release and disconnect high-voltage plugs (34, 35, 36).

41

Cover high-voltage connections with suitable protective covers.

 Set of protective covers

*001589019100

42

Disconnect coolant lines (37, 38, 39).

AR08.50-P-0018-01EQ

 Seal connections. Collect escaping coolant.

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

43

Lower vehicle.

44

Disconnect electrical connector (40).

45

Remove coolant lines (41, 42) from electric coolant pump.

AR08.50-P-0018-01EQ

 Seal connections. Collect escaping coolant.

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

46

Release bolts (43, 44) of engine carriers.

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

 Only release bolts (43, 44) by, in each case, one revolution.

 Screw, right engine carrier to frame

*BA22.10-N-1007-01TE

 Screw, left engine carrier to mounting support

*BA22.10-N-1008-01TE

47

Raise vehicle.

48

Prepare lifting platform (45).



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

 For this purpose, position raised lifting platform (45). Position supports at envisaged support points (hatched areas), align supports and secure in place in respective position and at respective height.

49

Lower lifting platform (45).

50

Slowly lower vehicle with vehicle lift until axle drive module (1) is in contact with supports of lifting platform (45).


Lower vehicle carefully.
Damage may occur otherwise.

 Aid of helper required.

51

Secure axle drive module (1) using tensioning strap at suitable location at lifting platform (45).

 Supports of lifting platform (45) must be correctly positioned and in contact with axle drive module (1).

 Commercially available devices/tools
Tensioning strap

If necessary



Align lifting platform (45).

52

Remove bolts (43, 44).

 Installation: Position bolts (43, 44) and slightly tighten by hand; however do not fully tighten.

If necessary for positioning of bolts (43, 44),



slightly raise lifting platform (45).

53

Remove axle drive module (1) with tubular frame.


For this purpose, carefully raise vehicle with vehicle lift.
Damage may occur otherwise.

 Several helpers required.

54

Install in the reverse order.

55

Perform commissioning of axle drive module (1) with vehicle diagnosis system.

When replacing axle drive module (1).



Connect/disconnect diagnostic unit

AD00.00-D-2000-06TS

 Engine mounts, engine supports

Number

Designation

Engine 780.703 in model 910

BA22.10-N-1007-01TE

Screw, right engine carrier to frame

Stage 1

Nm

58

Stage 2

°

90

 Engine mounts, engine supports

Number

Designation

Engine 780.703 in model 910

BA22.10-N-1008-01TE

Screw, left engine carrier to mounting support

Stage 1

Nm

58

Stage 2

°

90

 High-voltage on-board electrical system potential equalization ground lines

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1006-02TE

Nut, potential equalization ground line to body

Nm

16

 High-voltage on-board electrical system potential equalization ground lines

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1007-02TE

Screw, potential equalization ground line to DC/DC converter

Nm

16

 High-voltage on-board electrical system potential equalization ground lines

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1008-02TE

Nut, potential equalization ground line to high-voltage components holder in engine compartment

Nm

16

 High-voltage on-board electrical system potential equalization ground lines

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1009-02TE

Screw, potential equalization ground line/protective ground conductor to DC current charge-connection unit

Nm

7

 Battery

Number

Designation

Model 910

BA54.10-N-1003-01TS

Nut, ground line to body

Nm

20

 Air conditioning

Number

Designation

Model 910 with engine 780.703

BA83.30-N-1009-01TS

Nut, refrigerant line to refrigerant line

Nm

12