Check rear axle differential oil level, correct if necessary · ar3531p052003qbs · Mercedes-Benz WIS

AR35.31-P-0520-03QBS

Check rear axle differential oil level, correct if necessary

MODEL	204.377
	with CODE P98 (Black Series)
MODEL	209.377
	with CODE P98 (Black Series)

 Rear axle differential housing

Number	Designation		MODEL 204 with CODE P98
BA35.31-P-1005-02H	Threaded insert to rear axle differential housing	Nm	50

 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 204 with CODE P98
BA35.31-P-1006-02H	Banjo bolt for oil line to threaded chuck	Stage 1	Nm	5
		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-1007-02B	Banjo bolt for oil line to threaded chuck	Stage 1	Nm	5
		Stage 2	°	90

 Differential

Number	Designation			MODEL 209.377/477
BF35.31-P-1001-01K	Filling capacity	Differential	Liter	1,2
		Sheet		BB00.40-P-0235-61A

 Rear axle differential

Number	Designation			MODEL 204.377 with CODE P98, except CODEB25	MODEL 204.377 with CODE B25 and CODE P98
BF35.31-P-1001-01T	Filling capacity	Rear axle differential 187 FE, Ø 187 mm	Liter	–	–
		Sheet		-	-
		Rear axle differential 200 FE, Ø 200 mm	Liter	–	–
		Sheet		-	-
		Rear axle differential 215 FE, Ø 215 mm	Liter	1,2	1,35
		Sheet		BB00.40-P-0235-61A	BB00.40-P-0235-61A

129 589 00 91 00

Record plug

220 589 05 99 00

Electrical connection kit

Repair materials

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	Adolf Würth GmbH & Co. KG Reinhold-Würth-Str. 12-17 74653 Künzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax +49 7940 15-1000 www.wuerth.de
BR00.45-Z-1046-04A	Loctite 7063 cleaning spray (150 ml)	A 001 986 71 71 10
BR00.45-Z-1061-01A	Sealant, Omnifit 100H (50 g)	A 002 989 23 71

P35.31-2215-08

Shown on model 209.377

1	Differential	2	Cable	4	Connection
1a	Drain screw	2a	Sealing rings	M75	Rear axle differential cooling circuit oil pump
1b	Banjo bolt	3	Threaded insert

 Perform oil level check at room temperature only and not when the rear axle differential (1) is at operating temperature. Oil could otherwise escape if the rear axle differential (1) is at operating temperature.

1	Clean area around the banjo bolt (1b) and threaded insert (3).

2	Remove banjo bolt (1b) and remove line (2) with seal rings (2a).

 Collect any oil that escapes from the line (2) in an approved container.

3	Seal line (2) with  stop plug and tie upwards.

 The line opening must be located above the filler hole.

4	Unscrew threaded insert (3).

 Do not remove if rear axle differential (1) has to be prefilled.

 Collect escaping oil in approved container.

 Perform operation steps 5 to 14 only after replacing the rear axle differential coolant circuit oil pump (M75), lines, radiator or rear axle differential (1).

5	Prefill differential (1) with the specified oil quantity.

6	Mount line (2) with seal rings (2a) and banjo bolt (1b) on differential (1).

7	Release and disconnect rear axle differential cooling circuit temperature switch connector (X151).

8	Join plug contacts with adapter line  electrical connection kit.

9	Switch on ignition.

 Leave ignition switched on for max. 30 seconds.
The rear axle differential coolant circuit oil pump (M75) can otherwise be damaged.

 Switch on the ignition 2-times in succession for approx. 30 seconds with an interruption in each case of 1 minute.

 The running noise of the rear axle differential coolant circuit oil pump (M75) must become quieter as soon as oil flows through the rear axle differential coolant circuit oil pump (M75). If the rear axle differential coolant circuit oil pump (M75) does not run, determine and eliminate the cause subject to separate repair order.

10	Switch off ignition.

11	Disconnect adapter line and connect rear axle differential cooling circuit temperature switch connector (X15/1) together.

Shown on model 209.377

X15/1	Rear axle differential cooling circuit temperature switch connector
M75	Rear axle differential cooling circuit oil pump

P35.31-2214-12

12	Remove banjo bolt (1b) and remove line (2) with seal rings (2a).

 Collect any oil that escapes from the line (2) in an approved container.

13	Seal line (2) with  stop plug and tie upwards.

 The line opening must be located above the filler hole.

14	Unscrew threaded insert (3).

 The threaded insert (3) must be unscrewed from the filler hole.
The rear axle differential (1) will otherwise be overfilled and this could result in leakage, personal injury, damage to property and environmental pollution.

 Collect escaping oil in approved container.

15	Check oil level.

 Allow excess oil to flow out.
An incorrect filling quantity, leakage, personal injury, damage to property and environmental pollution can otherwise occur!

 When the oil level is correct the oil reaches the bottom edge of the oil filler hole in the differential (1).

16	Clean new threaded insert (3) as well as filler hole in differential (1).

 Replace threaded insert (3) whenever it is removed.
Leaks can otherwise occur.

17	Screw new threaded insert (3) into differential (1) and tighten.

 Apply a drop of sealant to the third thread from the bottom and immediately install the new threaded insert (3).

18	Mount line (2) with banjo bolt (1b) on differential (1).

 Install new sealing rings (2a).

19	Carry out leak check on differential (1) and connection points.

 Do not retighten or loosen the connector (4) if there is leakage .
The intake line will otherwise move out of the oil sump and the rear axle differential (1) can overheat. If connector (4) is leaky the end cover must be removed and connector (4) must be resealed.