Remove/install complete rear axle

AR35.10-P-0010QBS

Remove/install complete rear axle

09.03.2020

Model

209

with code P98 (Black Series)

1

Rear axle carrier

3l

Left brake cable

3r

Right brake cable

4

Oil line (return line)

5

Oil line (suction line)

10

Rear wheel

20

Propeller shaft

42

Brake caliper

49

Exhaust system

50

Rear axle gear

M75

Rear axle differential cooling circuit oil pump

1

Rear axle carrier

1h

Screw

1v

Screw

2

Connector strip

7

Underfloor paneling

32

Suspension strut

42

Brake caliper

50

Rear axle gear

 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

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

Topical note

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

AH00.00-P-0020-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on repair work on suspension components

AH00.00-P-0100-01A



Remove

1

Remove battery .

AR54.10-P-0005P

2

Remove cover panel and unhook left brake cable (3l) and right brake cable (3r) at intermediate lever and at intermediate lever housing.

 The cover panel is located under the battery.

 Dismantling tool

*000589956300

3

Secure vehicle on vehicle lift.

AR00.60-P-0100T

4

Remove rear wheels (10).



AP40.10-P-4050Z

5

Remove exhaust system (49) as of separating point and take out.

AR49.10-P-7000AC

6

Loosen underfloor paneling (7) at rear.

 Unscrew rear four nuts of the corresponding underfloor paneling (7) and press underfloor paneling (7) downward slightly.

7

Remove propeller shaft (20) from rear axle differential (50).

AR41.10-P-0050-03EA

 Tie propeller shaft (20) to one side and secure against falling down. The flex disk remains on the propeller shaft (20).

8

Loosen pilot bushing of flex disk at flange of rear axle differential (50).

AR41.10-P-0050-09DA



Drift for releasing the fitting sleeves in the flexible couplings

WF58.50-P-4110-01A

9

Remove brake caliper (42) with attached brake hoses and hang free of tension to one side.

AR42.10-P-0080AC

10

Remove torsion bar from rear axle.

AR32.20-P-0315P

 The torsion bar linkages remain on the wheel carriers.

11

Remove suspension struts (32) from spring links.

12

Disconnect electrical connectors of locking differential cooling circuit oil pump (M75) and of locking differential cooling circuit temperature switch and guide electric lines carefully through the rear axle carrier (1).

AR35.31-P-0595QBS

13

Remove locking differential cooling circuit oil pump (M75) from underbody and longitudinal member of rear axle carrier (1).

14

Unclip electrical connectors from connector strip (2).

15

Disconnect oil lines (4, 5) at connections to the oil cooler and seal with stop plugs.

AR35.31-P-0592-01QBS

 Secure oil lines (4, 5) using a cable strap at the carriers of the locking differential cooling circuit oil pump (M75).

 Record plug

*129589009100

16

Support rear axle with transmission plate and secure with tensioning strap to prevent it from falling down.

 Assembly support

*140589016200

17

Unscrew screws (1h, 1v) of rear axle carrier (1).


Do not use an impact wrench.
Otherwise, the threads will be damaged.

18

Lower rear axle.

19

Check, whether cavity preservation was performed on the rear axle carrier.

If not,



perform cavity preservation.

AR35.10-P-0010-03A



000 588 01 72 00 Sealing and corrosion protection gun

WS97.00-N-0002B

Cavity preservation (free of solvents), 1 liter

*BR00.45-Z-1003-05A



Install

20

Position rear axle at lay-on points.

21

Tighten screws (1h, 1v) of rear axle carrier (1).


Do not use an impact wrench.
Otherwise, the threads will be damaged.

 Recut thread in frame floor assembly and blow out with compressed air.

 Use new screw and new washer at torsion bar mounts.

 Self-locking bolt, front rear axle carrier rubber bushing to frame floor

*BA35.10-P-1001-01A

 Self-locking bolt, rear axle carrier rear rubber bushing to frame floor

*BA35.10-P-1002-01A

22

Loosen tensioning strap and remove transmission plate.

23

Remove stop plugs and attach oil lines (4, 5) to oil cooler.

AR35.31-P-0592-01QBS

 Replace locking clips and sealing rings of oil lines (4, 5).

24

Clip in electrical connectors to connector strip (2).

25

Attach locking differential cooling circuit oil pump (M75) to underbody and longitudinal member of rear axle carrier (1).

26

Guide electric line of locking differential cooling circuit oil pump (M75) and of locking differential cooling circuit temperature switch through rear axle carrier and connect electrical connector.

AR35.31-P-0595QBS

27

Attach suspension struts to spring links (32) and tighten screws lightly by hand.

 Fasten screws of the suspension struts (32) at the spring links only after the wheel alignment measurement.

 Self-locking nut for attaching shock absorber to spring control arm

*BA32.25-P-1003-03A

28

Attach torsion bar to rear axle.

AR32.20-P-0315P

29

Attach brake calipers (42).

AR42.10-P-0080AC

30

Guide in pilot bushing of flex disk at flange of rear axle differential (50).

31

Attach propeller shaft (20) to rear axle differential (50).

AR41.10-P-0050-04EA

 Replace nuts.

 Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential

*BA41.10-P-1002-01A

 Torque wrench

*001589662100

32

Attach rear underfloor paneling (7).

33

Install exhaust system (49).

AR49.10-P-7000AC

34

Mount rear wheels.



AP40.10-P-4050Z

35

Remove vehicle lift safety device.

36

Hook in left brake cable (3l) and right brake cable (3r) at the intermediate lever and the intermediate lever housing and attach cover panel.

37

Install battery.

AR54.10-P-0005P



Check

38

Check and correct oil level in rear axle differential(50).

Model 209
with code P98 (Black Series)

Model 209.377
with code P98 (Black Series)

AR35.31-P-0520-03QBS

 Model 209.377
with code P98 (Black Series)Filling capacity

*BF35.31-P-1001-01K

 Model 209.377
with code P98 (Black Series)Banjo bolt for oil line to threaded chuck

*BA35.31-P-1007-02B

 Model 209.377
with code P98 (Black Series)Threaded chuck to rear axle differential housing

*BA35.31-P-1006-02B

Sealant, Omnifit 100H (50 g)

*BR00.45-Z-1061-01A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

Assembly cleaner

*BR00.45-Z-1028-04A

 Electrical connection kit

*220589059900

 Record plug

*129589009100



Measure

39

Perform chassis alignment.

AR40.20-P-0200P

 Rear axle shock absorber

Number

Designation

Model 209
with code P98 (Black Series)

BA32.25-P-1003-03A

Self-locking nut for attaching shock absorber to spring control arm

–

Stage 1

Nm

70

Stage 2

°

–

M10

Nm

–

 Rear axle carrier

Number

Designation

Model 209
with code P98 (Black Series)

BA35.10-P-1001-01A

Self-locking bolt, front rear axle carrier rubber bushing to frame floor

–

Nm

–

With Ø 24 mm bolted flange

Stage 1

Nm

–

Stage 2

°

–

With Ø 26 mm bolted flange

Stage 1

Nm

40

Stage 2

°

90

 Rear axle carrier

Number

Designation

Model 209
with code P98 (Black Series)

BA35.10-P-1002-01A

Self-locking bolt, rear axle carrier rear rubber bushing to frame floor

–

Nm

–

With Ø 24 mm bolted flange

Stage 1

Nm

–

Stage 2

°

–

With Ø 26 mm bolted flange

Stage 1

Nm

80

Stage 2

°

90

 Rear axle differential housing

Number

Designation

MODEL 203.07/27, MODEL 209.372/ 377/472/477, MODEL 209.375/ 376/475/476 as of 24.04.04

BA35.31-P-1006-02B

Threaded chuck to rear axle differential housing

60

 Rear axle differential housing

Number

Designation

MODEL 203.07/27, MODEL 209.372/ 377/472/477, MODEL 209.375/ 376/475/476 as of 24.04.04

BA35.31-P-1007-02B

Banjo bolt for oil line to threaded chuck

Stage 1

Nm

5

Stage 2

°

90

 Propeller shaft

Number

Designation

Model 209

BA41.10-P-1002-01A

Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential

M10

Nm

36

M12

Nm

58

 Differential

Number

Designation

Model 209.377/477

BF35.31-P-1001-01K

Filling capacity

Differential

Liter

1,2

Sheet

BB00.40-P-0235-61A

Repair materials

Number

Designation

Order number

BR00.45-Z-1003-05A

Cavity preservation (free of solvents), 1 liter

A 000 986 72 70 10

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09

BR00.45-Z-1061-01A

Sealant, Omnifit 100H (50 g)

A 002 989 23 71