Remove/install rear axle shaft

AR35.30-P-0620P

20.6.11

MODEL 203, 209
Rear axle shaft plugged in

P35.30-2066-09

Illustration shows left side of rear axle

2 Camber strut

3 Torque strut

4 Tie rod

5 Thrust arm

61 Brake disk

111 Brake caliper

L6/3 Left rear rpm sensor

6k Torsion bar connecting rod

7 Wheel carrier

37 Rear axle shaft

40 Twelve-point collar nut

Modification notes

21.6.11

Value modified: Filling capacity

Model 203.040/042/043/046/052/081/084/087/092/240/242/243/246/252/281/284/287/292/707/730/731/740/742/743/746, Model 203.004/061/204/261, as of 09/2002, Model 203.007/207 without taxi version

Model 209.341/342/343/361/441/442/461

*BF35.31-P-1001-01K

 	Remove/install
Danger!	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
 Installation	The rear axle shaft (37) must be horizontal (suspension compressed) when the torque strut (3) is tightened, to ensure that the axle geometry is not influenced.
1	Raise vehicle		AR00.60-P-1000P
2	Remove twelve-point collar nut (40) from rear axle shaft (37)	 To prevent wheel bearing damage the vehicle must not be moved on its wheels any more once the twelve-point collar nut (40) is loosened.	AR35.30-P-0115-01A
		 Installation: Replace twelve-point collar nut (40).
			*BA35.30-P-1001-01A
3	Remove rear wheel
	Remove/install wheels		AP40.10-P-4050Z
4	Remove brake caliper (111) from the rear axle	 To relieve the strain on the brake hose, fasten the rear brake caliper (111) onto the vehicle free of tension so that it is not damaged during repair work.
		Model 203, Model 209.316 /341 /342 /343 /361 /365 /372 /375 /441 /442 /461 /465 /472 /475, 209.376 /476 up to 23.4.04	AR42.10-P-0080P
		Model 209.376/476 as of 24.4.04, Model 209.377/477	AR42.10-P-0080AC
5	Remove torque strut (3) from wheel carrier (7)	Model 203, 209 except code (P98) Black Series	AR35.20-P-0111P
		Model 209 with code (P98) Black Series	AR35.20-P-0111QBS
6	Detach camber strut (2) from wheel carrier (7).		AR35.20-P-0110P
7	Detach tie rod (4) from wheel carrier (7)	Model 203, 209 except code (P98) Black Series	AR35.20-P-0112P
		Model 209 with code (P98) Black Series	AR35.20-P-0109QBS
8	Remove thrust arm (5) from wheel carrier (7)		AR35.20-P-0113P
9	Fold wheel carrier (7) outwards and simultaneously press the rear axle shaft (37) out of the rear axle shaft flange	 Do not overstretch the brake cable (arrow) to avoid any damage.	AR35.30-P-0115-03BF
		 Do not damage the rubber boots of the rear axle shaft (37) and pulse ring for the left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4), otherwise the electronic stability program (ESP) will not function correctly.
		 Fold wheel carrier (7) back and secure to prevent it from falling down.
			*210589034300
			*210589014000
10	Pull rear axle shaft (37) out of rear axle differential.		AR35.30-P-0620-02P
	Checking
11	Check constant velocity joints and rubber boots	 If the constant velocity joint is defective, the rear axle shaft (37) must be completely replaced.
		If damaged or leaking: 
		Replace constant velocity joint or rubber boot on rear axle shaft.	AR35.30-P-0661P
12	Check radial sealing ring in rear axle housing	If damaged or leaking: 
		Replace radial sealing ring of rear axle shaft at rear axle gear housing.	AR35.31-P-0541P
13	Install in the reverse order
14	Check oil level in rear axle differential and correct if necessary	Model 203 and model 209 except code (P98) Black Series	AR35.31-P-0520-03P
		Model 209 with code (P98) Black Series	AR35.31-P-0520-03QBS
		 In the interest of better fuel economy, avoid mixing old universal hypoid gear oil with new FE hypoid gear oil.
		 New oil filling/oil drain screws should be used with rear axle differential diameter 185, 187, 198, 210 up to production date 18.1.04. 
	Oil filler/drain screw on rear axle differential modified	up to 18.1.04	BT35.31-P-0015-01A
			*BA35.31-P-1001-02B
			*BF35.31-P-1001-01K
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
		Omnifit sealing compound 100H (50 g)	*BR00.45-Z-1061-01A

 Rear axle shaft

Number	Designation			Model 203	Model 209 except 209.377/ 477, model 209 without code P98	Model 209.377/ 477, model 209 with code P98


BA35.30-P-1001-01A	Collar nut, rear axle shaft to rear axle shaft flange	self-locking	Nm	-	-	350
		not self-locking	Nm	220	220	320