Rear strut removal and installation - AR32.25-P-1016A

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

MODEL 140 as of 1.6.94, 210 with CODE (217a) Self-levelling suspension on rear axle with ADS with CODE (480) Level control system at rear

MODEL 202, 203.2, 208 with CODE (480) Level control system at rear

Fig 1: Identifying Rear Strut Components (Model 140, 202, 208, 203.2, 210.0)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Strut on Model Series 210.2, 210.6

Fig 2: Identifying Rear Strut Components (Strut On Model Series 210.2, 210.6)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Strut on Model Series 203.2

Fig 3: Identifying Rear Strut Components (Strut On Model Series 203.2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing, installing
	The vehicle must be standing on its wheels for removing the top spring strut mounting.
1	Remove trim panels from luggage compartment /cargo area
2	Remove top spring strut mounting	Model Series 140 Use Allen wrench (5 mm) to hold piston rod and prevent it from turning.
		Model Series 202, 208, 210.0	Figure
		Installation: Replace self-locking nut (5a) on Model 140. Model Series 140 nut (5a) *BA32.30-P-1001-01A
		Model Series 202, 203, 208 nut (5p)	*BA32.30-P-1001-01B
		Model Series 210.0 nut (5p)	*BA32.30-P-1006-01A
		Model Series 202, 208 nut (5a)	*BA32.30-P-1002-01B
		Model Series 210.0 nut (5a)	*BA32.30-P-1005-01A
		210.2, 210.6 Bolt (5g)	*BA32.30-P-1007-01A
3.1	Remove washer (5b) and rubber mount (5c)	Model Series 202, 203, 208, 210.0
3.2	Remove washer (5i) and rubber bushing (5c)	Model Series 210.2, 210.6
4	Cover all attached parts remaining in vehicle (area to be repaired)
	Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning from swallowing hydraulic fluid.	Render the hydraulic system pressureless before commencing work on system. Wear protective clothing and eye protection.	AS00.00-Z-0013-01A
5	Drain hydraulic system	Installation: Recharge hydraulic system	AR32.30-P-0630A
	General notes for working on vehicles with level control / ADS	All models with Code 216b, 216c, 217a, 480	AH32.00-P-0002-01A
6.1	Disconnect high-pressure supply line (P4) at the joint where the steel pipe joins the hose	Model Series 140, 210.2, 210.6 Installation: Ensure that the high-pressure supply line (P4) is routed correctly.
		Model Series 140	*BA32.30-P-1003-01A
		Model Series 210.2, 210.6	*BA32.30-P-1003-01A
6.2	Disconnect high-pressure supply line (P4) from strut	Model Series 202, 203, 208, 210.0
		Model Series 202, 208	*BA32.30-P-1004-01B
		Model Series 210.0	*BA32.30-P-1004-01B
		Installation: Replace radial seals at the banjo bolt (5v)
		Before tightening pressure line at spring strut ↓ Check, adjust distance between strut and wheel-housing	AR32.30-P-0610-01A
7	Remove cover from track control arm (72c)
8	Detach and remove spring strut (5) from spring link (72)	Installation: Pull apart spring strut so that the spring strut mount rests in the dome. Model Series 140: The metal plate on the strut bushing must be toward the front of the vehicle. Replace self-locking nut (5n).
		Model Series 140	*BA32.30-P-1003-01B
		Model Series 202, 203, 208	*BA32.30-P-1002-01A
		Model Series 210	*BA32.30-P-1002-01A
	Inspecting
9	Check rubber bushings (5c, 5d), strut bearing support (5e) and rubber boot for cracks and damage. Check ball joint for wear
10	Check spring strut for leaks.	A fine oil mist is permitted. If the joint socket is covered with oil ↓ replace the strut.
11	Reverse the removal sequence to install	after installation: Check distance between strut and wheel-housing with the vehicle ready to roll.
		Model Series 202, 203, 208, 210.0: Loosen the upper strut mount and re-align the strut as necessary.	AR32.30-P-0610-01A
	Injury hazard! Drilling into gas-filled assemblies and components represents a potential injury hazard (the gas itself is not flammable)	Wear safety glasses and face mask.	AS00.00-Z-0006-01A
12	Dispose of shock-absorber strut
			OS32.25-P-0120-01A

Rear strut test specifications

Number	Designation				Model Series 202 with ride-height control	Model Series 203.2 with self-leveling suspension
BE32.30-P-1001-01A	Distance between supply hose bracket on strut and wheel-housing	with suspension extended	left	mm	11-15	11-15
			right	mm	24-28	24-28
			Fig. see		AR32.30-P-0610-01A	AR32.30-P-0610-01A
BE32.30-P-1002-01A	Distance between supply hose bracket on strut and wheel-housing	ready to roll (standing on wheels)	left	mm	14-18	14-18
			right	mm	26-30	26-30
			Fig. see		AR32.30-P-0610-01A	AR32.30-P-0610-01A

Rear strut test specifications

Number	Designation				Model 210.0 with level control system / AD	Model Series 208 with self-leveling suspension
BE32.30-P-1001-01A	Distance between supply hose bracket on strut and wheel-housing	with suspension extended	left	mm	8.5-10.5	11-15
			right	mm	8.5-10.5	24-28
			Fig. see		AR32.30-P-0610-01A	AR32.30-P-0610-01A
BE32.30-P-1002-01A	Distance between supply hose bracket on strut and wheel-housing	ready to roll (standing on wheels)	left	mm	10.5-12.5	14-18
			right	mm	10,5-12,5	26-30
			Fig. see		AR32.30-P-0610-01A	AR32.30-P-0610-01A

Rear strut

Number	Designation		Model Series 202 with ride-height control	Model Series 203.2 with self-leveling suspension
BA32.30-P-1001-01B	Nut of spring strut of level control to frame floor	NM	18	18
BA32.30-P-1002-01B	Locknut of spring strut of level control to frame floor	NM	30	30
BA32.30-P-1003-01B	Self-locking nut, ride-height control strut to track control arm	NM	55	55
BA32.30-P-1004-01B	Banjo bolt of pressure pipe of level control to spring strut	NM	25	25

Rear strut

Number	Designation		Model Series 208 with ride-height control
BA32.30-P-1001-01B	Nut of spring strut of level control to frame floor	NM	18
BA32.30-P-1002-01B	Locknut of spring strut of level control to frame floor	NM	30
BA32.30-P-1003-01B	Self-locking nut, ride-height control strut to track control arm	NM	55
BA32.30-P-1004-01B	Banjo bolt of pressure pipe of level control to spring strut	NM	25

Rear strut

Number	Designation			Model Series 140 with ride-height control/ ADS	Model 210.0 with level control system / ADS
BA32.30-P-1001-01A	Self-locking nut, strut for self-leveling suspension/ADS to floorpan		NM	40	-
BA32.30-P-1002-01A	Self-locking nut, ride-height control/ADS strut to track control arm		NM	100	55
BA32.30-P-1003-01A	High-pressure supply line for self-leveling suspension at joint between strut steel pipe and supply hose (reference figure)	M16 x 1.5	NM	30	30
BA32.30-P-1004-01A	Banjo bolt, pressure pipe of level control to spring strut		NM	-	25
BA32.30-P-1005-01A	Locknut of spring strut of level control to frame floor		NM	-	30
BA32.30-P-1006-01A	Nut of spring strut of level control to frame floor		NM	-	17

Rear strut

Number	Designation			Model Series 210.2 with self-leveling suspension/ ADS
BA32.30-P-1002-01A	Self-locking nut, ride-height control/ADS strut to track control arm		NM	55
BA32.30-P-1003-01A	High-pressure supply line for self-leveling suspension at joint between steel pipe on strut and supply hose (reference figure)	M16 x 1.5	NM	30
BA32.30-P-1007-01	Bolt, self-leveling suspension strut to frame		NM	25

Fig 4: Identifying Socket Wrench (202 589 00 09 00) Socket Wrench

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.