Disassembling and assembling rear axle differential, adjusting gear set

AR35.31-P-0550B

Disassembling and assembling rear axle differential, adjusting gear set

2.3.10

17.5.04

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 drain screw must always be replaced after being unscrewed from the rear axle center assembly.

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

AR35.31-P-0520-06A

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.

Model 170, 202, 210

AR35.31-P-0520-03A

Model 124, 201

AR35.31-P-0520-03AA



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.

AS00.00-Z-0010-01A

1

Raise vehicle with vehicle lift

2

Drain oil from rear axle differential (50)

AR35.31-P-0520-06A

Cleaning spray, Loctite 7063 (150ml)

*BR00.45-Z-1046-04A

Sealant, Omnifit 100H (50 g)

*BR00.45-Z-1061-01A

 Oil drain screw

*BA35.31-P-1003-02A



Oil filler/drain screw on rear axle differential modified

Phased in as of 19.01.04

BT35.31-P-0015-01A

3

Remove rear axle differential (50)

Model 124, 201

ra35001240520x

Model 170, 202

AR35.31-P-0520D

Model 210

AR35.31-P-0520B



Tapped hole for rpm sensor relocated at rear axle housing

Model 124, 201

BT35.31-P-0004-01A



Features, installation survey for rear axle differentials

GF35.31-P-1000-01B



Disassemble

4

Clamp rear axle differential (50)  in assembly stand.



AR35.31-P-0540-06B

5

Remove end cover (54)



End cover (54) with unmachined sealing surface

Model 170, 202, 210 as of 08.05.00

BT35.31-P-0014-01A

6

Detach retaining rings (30) from both connecting flanges (33 or 33d)



AR35.31-P-0540-01A

7

Pull out connecting flanges (33 or 33d).

8

Pry off left and right radial sealing ring (32)

AR35.31-P-0540-05E

9

Remove shim (31a) from face of differential case

10

Using the  spreader, remove the left-hand circlip (29) from the rear axle housing

  Mark circlip (29).

AR35.31-P-0550-01B

11

Remove right circlip (29) from rear axle case using spreader

 Mark the retaining ring (29).

12

Remove both tapered roller bearing outer races (11a) out of rear axle housing

  Mark tapered roller bearing outer races (11a)

AR35.31-P-0550-02B

13

Take differential (13) out of rear axle housing

AR35.31-P-0550-03B

14

Detach both tapered roller bearing inner races (11b) from differential (13)

  Mark tapered roller bearing inner races (11b).

AR35.31-P-0550-04B

15

Loosen and remove retaining bolts (13a) from crown wheel (47a)

 Mark position of ring gear (47a) in relation to differential (13).

16

Carefully press off crown wheel (47a) from differential (13)

17

Loosen and remove twelve-point collar nut (40) from joint flange (41).



AR35.31-P-0550-35B

18

Detach joint flange (41).

  If necessary, mark joint flange (41) relative to drive pinion.

AR35.31-P-0550-06B

19

Push drive pinion (47) out of rear axle housing



AR35.31-P-0550-07B

20

Press radial sealing ring (42) out of the rear axle housing using a suitable screwdriver.

AR35.31-P-0550-08B

21

Remove tapered roller bearing inner race (43d)

22

Remove tapered roller bearing outer races (46b, 43e) and shim (45) from rear axle housing.



AR35.31-P-0550-09B

23

Remove spacer sleeve (44) with thrust plates (48) from drive pinion (47)

24.1

Pull ABS gear (49) off drive pinion (47).

 Vehicles with antilock brake system (ABS) code 470a, except vehicles with ETS, ASR, ESP

AR35.31-P-0550-30B

25

Pull tapered roller bearing inner race (46a) from drive pinion (47)



AR35.31-P-0550-10B



Checking

26

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.

27.1

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.

AR35.31-P-0550-11A

 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

BT35.31-P-0011-01B



Assembly, adjusting ring gear and pinion

28

Press tapered roller bearing inner race (46a) onto drive pinion (47)

AR35.31-P-0550-12B



Press-on sleeve for tapered roller bearing inner race

WF58.50-P-3531-03B

29.1

Press ABS gear (49) onto drive pinion (47).

Vehicles with antilock brake system (ABS) code 470a, except vehicles with ETS, ASR, ESP

AR35.31-P-0550-31B



Press-on sleeve for ABS gear

WF58.50-P-3531-04B

Number of teeth on ABS gear: 



Features, installation survey for rear axle differentials

GF35.31-P-1000-01B

30

Calculate shim (45) and installing in rear axle housing

  Use data sheet: 

AR35.31-P-0550-13B

Data sheet, Adjusting rear axle gear set:

Order No. B20.800.98.113.00C

31

Pull tapered roller bearing outer races (43e, 46b) into rear axle housing



AR35.31-P-0550-14B

32

Install spacer sleeve (44) on drive pinion (47) with double-sided thrust plates (48)

 Always replace spacer sleeve (44) and thrust plates (48).

AR35.31-P-0550-26B

33

Insert drive pinion (47) into rear axle housing.

  Support drive pinion (47) with removal and installation tool.

AR35.31-P-0550-15B

34

Place tapered roller bearing inner race (43d) onto drive pinion gear (47) and press in together with radial sealing ring (42)

  Replace radial sealing ring (42) and coat the lip with universal hypoid gear oil.

AR35.31-P-0550-16B



Universal hypoid gear oils

BB00.40-P-0235-07A



Modified radial sealing ring

Model 124, 201

BT35.31-P-0008-01A

35

Slide joint flange (41) onto drive pinion (47)

 Possibly observe applied marking. Coat contact face for radial sealing ring with universal hypoid gear oil.



Universal hypoid gear oils

BB00.40-P-0235-07A



Protection ring on drive pinion joint flange lengthened

Model 124, 201

BT35.31-P-0003-01A



Imbalance on drive pinion joint flange reduced

Model 124, 201

BT35.31-P-0007-01A



Hole diameter of drive pinion joint flange increased

Model 124, 201

BT35.31-P-0010-01A

36

Screw on twelve-point collar nut (40).

 Install new twelve-point collar nut (40).

 Socket

*201589000900

37

Adjusting friction torque of drive pinion bearing



AR35.31-P-0550-17B

38

Check adjustment dimension for drive pinion (47)



AR35.31-P-0550-18B

39

Secure twelve-point collar nut (40) on joint flange (41).

AR35.31-P-0530-01B



Caulker for securing twelve-point collar nut (40) on joint flange (41)

WF58.50-P-3531-01A

40

Dismantling and assembling differential (13)



AR35.31-P-0560B

41

Mount ring gear (47a) onto differential (13)

  Observe marking applied to ring gear (47a) and differential (13).

AR35.31-P-0550-19B



Tightening torque of ring gear bolts reduced

Model 124, 201 as of 01.02.87

BT35.31-P-0005-01A

42

Press tapered roller bearing inner races (11b) onto differential (13)



AR35.31-P-0550-20B

43

Install differential (13) in rear axle housing

AR35.31-P-0550-03B

44

Insert right tapered roller bearing outer race (11a) in rear axle housing



AR35.31-P-0550-21B

45

Insert right circlip (29)

  Install the circlip (29) removed and marked previously in order to achieve a basic pretension of the rear axle housing.

AR35.31-P-0550-22B

46

Take left-hand  drift out of differential (13)

47

Insert left tapered roller bearing outer race (11a) into rear axle housing

 Tapered roller bearing outer race (11a) must contact the tapered roller bearing inner race (11b).

48

Pre-tension (spread) rear axle housing with spreader



AR35.31-P-0550-23B

49

Insert left circlip (29)

  Install the circlip (29) removed and marked previously in order to achieve a basic pretension of the rear axle housing.

AR35.31-P-0550-27B

50

Release rear axle housing

51

Measure expanded dimension of rear axle housing



AR35.31-P-0550-24B

52

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).

AR35.31-P-0550-25B

53

 Dismantle spreader and stop from rear axle housing

54

Check that circlip (29) is correctly seated.



AR35.31-P-0550-32B

55

Place shim (31a) in differential (13)

 Shim (31a) must press firmly against end face of differential.

AR35.31-P-0550-33B

56

Press radial sealing rings (32) into the rear axle housing

  Replace radial sealing ring (32) and coat the lip with universal hypoid gear oil.

AR35.31-P-0540-05E



Universal hypoid gear oils

BB00.40-P-0235-07A



Radial sealing rings modified

Model 124, 201

BT35.31-P-0008-01A

57

Install connecting flanges (33 or 33d) in differential (13)



Connecting flange with centering

Model 124, 201

BT35.31-P-0009-01A

58

Install retaining rings (30) on both connecting flanges (33 or 33d)

  Replace circlip (30).

AR35.31-P-0540-01A

59

Check axial play of connecting flange (33 or 33d), adjust if necessary

AR35.31-P-0540-02D

60

Attach end cover (54)

 If a replacement part end cover is mounted, it is essential to observe whether the sealing surface is machined or unmachined. Use suitable sealant.

End cover (54) with machined sealing surface in models 124, 201 and in models 170, 202, 210 up to 07.05.00

AR35.31-P-0550-28B

End cover (54) with unmachined sealing surface in models 170, 202, 210 as of 08.05.00

AR35.31-P-0550-28BA



Rear axle differential end cover with non-machined sealing surface

Model 170, 202, 210 as of 08.05.00

BT35.31-P-0014-01A

61

Replace rear axle breather (55) on end cover (54)



*BA35.31-P-1005-02A

62

Remove rear axle differential (50) from  assembly stand



Install

63

Install rear axle differential (50).

Model 124, 201

ra35001240520x

Model 170, 202

AR35.31-P-0520D

Model 210

AR35.31-P-0520B

64

Pour oil into the rear axle differential (50)

Model 170, 202, 210

AR35.31-P-0520-03A

 170

*BF35.31-P-1001-01F

 202

*BF35.31-P-1001-01D

 210

*BF35.31-P-1001-01E

Cleaning spray, Loctite 7063 (150ml)

*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

Model 124, 201

AR35.31-P-0520-03AA

 124

*BF35.31-P-1001-01B

 201

*BF35.31-P-1001-01G

Cleaning spray, Loctite 7063 (150ml)

*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 124.020/021/
080/081/120/ 125/126/180/185,
except (code 450) taxi version

Model 124.020/021/
080/081/120/
125/126/180/
185/186,
with (code 450) taxi version
up to 31.10.88

Model 124.104/107
up to 30.04.94
Model 124.105/106
Model 124.186
up to 28.02.94,
except (code 450)
Taxi version

BE35.31-P-1001-02B

Friction torque of drive pinion bearing (new tapered roller bearings)

Ncm

120-140

120-140

120-140

Number

Designation

Model 170.435

Model 201.018/023/
024/122/126, except (code 450) taxi version

Model 201.018/023/
024/122/126,
with (code 450)
Taxi version
up to 31.10.88

BE35.31-P-1001-02B

Friction torque of drive pinion bearing (new tapered roller bearings)

Ncm

120-140

120-140

120-140

Number

Designation

Model 202.018/078/120/
121/122/125/182,
except (code 450)
taxi version,
Model 202.018/120/121/
125
without ASD (code 211),
Model 202.180

Model Series 210.003/004 except (Code 450) Taxi version

BE35.31-P-1001-02B

Friction torque of drive pinion bearing (new tapered roller bearings)

Ncm

120-140

120-140

Number

Designation

Model 124

Model 170

Model 201

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

-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

0,08-0,14

BE35.31-P-1003-03A

Crown wheel heating temperature for installation

°C

75-85

75-85

75-85

Number

Designation

Model 202

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

Number

Designation

Model 124.020/021/ 080/081/120/125/126/ 180/185
except (code 450)
taxi version

Model 124.020/021/
080/081/120/125/ 126/180/185/186,
with (code 450) taxi version
up to 31.10.88

Model 124.104/107
up to 30.04.94,
Model 124.105/106
Model 124.186
up to 28.02.94,
except (code 450)
taxi version

BE35.31-P-1001-04B

Rear axle housing expansion (spread dimension) for circlip removal

mm

0.2

0.2

0.2

BE35.31-P-1002-04B

Rear axle housing expansion (spread dimension) when installing circlip

mm

0.25

0.25

0.25

BE35.31-P-1003-04B

Setting for rear axle housing expansion (spread dimension)

mm

0,13-0,18

0,13-0,18

0,13-0,18

Number

Designation

Model 170.435

Model 201.018/023/
024/122/126, except (code 450) taxi version

Model 201.018/023/
024/122/126,
with (code 450)
Taxi version
up to 31.10.88

BE35.31-P-1001-04B

Rear axle housing expansion (spread dimension) for circlip removal

mm

0.2

0.2

0.2

BE35.31-P-1002-04B

Rear axle housing expansion (spread dimension) when installing circlip

mm

0.25

0.25

0.25

BE35.31-P-1003-04B

Setting for rear axle housing expansion (spread dimension)

mm

0,13-0,18

0,13-0,18

0,13-0,18

Number

Designation

Model 202.018/078/120/
121/122/125/182, except (code 450)
Taxi version,
Model 202.018/120/121/
125
without ASD (code 211),
Model 202.180

Model Series 210.003/004 except (Code 450) Taxi version

BE35.31-P-1001-04B

Rear axle housing expansion (spread dimension) for circlip removal

mm

0.2

0.2

BE35.31-P-1002-04B

Rear axle housing expansion (spread dimension) when installing circlip

mm

0.25

0.25

BE35.31-P-1003-04B

Setting for rear axle housing expansion (spread dimension)

mm

0,13-0,18

0,13-0,18

Number

Designation

Model 124

Model 170

Model 201

Model 202

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

0.03 to 0.3

Number

Designation

Model
124

Model
170

BA35.31-P-1001-02A

Bolt, end cover to rear axle differential

Bolt+washer

Nm

50

-

Flange bolt
(TORX, internal serrations)

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

25

Number

Designation

Model
201

Model
202

BA35.31-P-1001-02A

Bolt, end cover to rear axle differential

Bolt+washer

Nm

50

50

Flange bolt
(TORX, internal serrations)

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

25

Number

Designation

Model
210

BA35.31-P-1001-02A

Bolt, end cover to rear axle differential

Bolt+washer

Nm

50

Flange bolt
(TORX, internal serrations)

Stage 1

Nm

30

Stage 2

°

45

BA35.31-P-1002-02A

Oil filler screw, rear axle differential

Nm

50

BA35.31-P-1003-02A

Oil drain screw for rear axle differential

Nm

50

BA35.31-P-1005-02A

Breather, rear axle differential

Nm

30

Number

Designation

Model 124.020/021/
080/081/120/
125/126/180/185,
except (code 450)
taxi version

Model 124.020/021/
080/081/120/
125/126/180/
185/186,
with (code 450)
taxi version
up to 31.10.88

Model 124.104/107
up to 30.04.94,
model 124.105/106,
model 124.186
up to 28.02.94,
except (code 450)
taxi version

Model 170.435

BA35.31-P-1001-03B

Retaining bolt, ring gear to differential case

Nm

85

85

85

85

Number

Designation

Model 201.018/023/
024/122/126,
except (code 450) taxi version

Model
201.018/023/
024/122/126,
with (code 450) taxi version up to 31.10.88

Model 202.018/078/120/
121/122/125/182, except (code 450)
taxi version,
Model 202.018/120/121/
125
without ASD (code 211),
Model 202.180

BA35.31-P-1001-03B

Retaining bolt, ring gear to differential case

Nm

85

85

85

Number

Designation

Model 210.003/004
except (code 450)
taxi version

BA35.31-P-1001-03B

Retaining bolt, ring gear to differential case

Nm

85

Number

Designation

Model 124.104 /107
up to 30.04.94
without (code 211) ASD
Model 124.105/106
without (code 211) ASD
Model 124.186
without (code 211) ASD
up to 28.02.94,
except (code 450)
taxi version

Model 124.020/021/080/
081/120/125/126/180/
185,
without (code 211) ASD, except (code 450)
taxi version

BF35.31-P-1001-01B

Filling capacity

Rear axle center assembly

Liters

0.7

0.7

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

Number

Designation

Model 124.020/021/080/
081/120/125/126/180/
185/186,
without (code 211) ASD, with (code 450)
taxi version
up to 31.10.88

BF35.31-P-1001-01B

Filling capacity

Rear axle center assembly

Liters

0.7

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-00A

Sheet

BB00.40-P-0235-07A

Number

Designation

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

BF35.31-P-1001-01D

Filling capacity

Rear axle center assembly

Liters

0.7

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-00A

Sheet

BB00.40-P-0235-07A

Number

Designation

Model 210.003/004 except code 450

BF35.31-P-1001-01E

Filling capacity

Rear axle center assembly

Liters

0.7

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

Number

Designation

Model 170.435

BF35.31-P-1001-01F

Filling capacity

Rear axle center assembly

Liters

0.7

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-07A

Number

Designation

Model 201.018/023/
024/122/126,
without (code 211) ASD,
except (code 450) taxi version

Model 201.018/023/
024/122/126, without (code211) ASD, with (code 450) taxi version up to 31.10.88

BF35.31-P-1001-01G

Filling capacity

Rear axle center assembly

Liters

0.7

0.7

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-00A

BB00.40-P-0235-00A

Sheet





Number

Designation

Order number

BR00.45-Z-1061-01A

Sealant, Omnifit 100H (50 g)

A 002 989 23 71

BR00.45-Z-1010-01A

Hylomar universal sealant 80 ml

A 001 989 25 20

BR00.45-Z-1013-01A

Loctite sealant 5970

A 003 989 98 20

BR00.45-Z-1046-04A

Cleaning spray, Loctite 7063 (150ml)

A 001 986 71 71 10