Rear axle center piece with 210 mm dia. crown wheel (reinforced) - RA3500HMV0550X(35-550)

Preceding work:

Removing and installing rear axle center piece (35-520)

Operation no. of operation texts and work units or standard texts and flat rates: 35-0815

Fig 1: Identifying Rear Axle Center Piece Components

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Special tools 

Fig 2: Identifying Special Tool (129 589 00 31 00 35)

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Fig 3: Identifying Special Tool (116 589 01 62 00 42)

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Fig 4: Identifying Special Tool (129 589 02 43 00 35)

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Fig 5: Identifying Special Tool (123 589 08 33 00 33 35)

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Fig 6: Identifying Special Tool (000 589 65 33 00 00 26)

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Fig 7: Identifying Special Tool (000 589 88 33 00 00)

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Fig 8: Identifying Special Tool (116 589 12 33 00 26)

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Fig 9: Identifying Special Tool (129 589 01 07 00 26 28 35 83)

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Fig 10: Identifying Special Tool (126 589 02 09 00 26 27 28 35)

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Fig 11: Identifying Special Tool (129 589 01 33 00 26 35)

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Fig 12: Identifying Special Tool (140 589 10 43 00 35)

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Fig 13: Identifying Special Tool (001 589 36 33 00 26 33 35)

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Fig 14: Identifying Special Tool (000 589 35 34 00 35)

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Fig 15: Identifying Special Tool (140 589 02 34 00 35)

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Fig 16: Identifying Special Tool (140 589 00 01 00 26 28 33 35)

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Fig 17: [Figure Not Found]

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Fig 18: Identifying Special Tool (140 589 16 23 00 35)

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Fig 19: Identifying Special Tool (140 589 07 21 00 35)

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Fig 20: Identifying Special Tool (116 589 01 21 00 35)

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Fig 21: Identifying Special Tool (140 589 25 63 00 35)

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Fig 22: Identifying Special Tool (111 589 08 23 00 35)

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Fig 23: Identifying Special Tool (115 589 05 21 00 35)

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Fig 24: Identifying Special Tool (140 589 01 43 00 35)

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Fig 25: Identifying Special Tool (140 589 02 15 00 35)

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Fig 26: Identifying Special Tool (001 589 49 21 00 00 28 33 35)

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Fig 27: Identifying Special Tool (100 589 02 59 00 00)

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Fig 28: Identifying Special Tool (140 589 03 15 00 35)

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Fig 29: Identifying Special Tool (140 589 04 15 00 35)

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Fig 30: Identifying Special Tool (140 589 09 15 00)

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Fig 31: Identifying Special Tool (116 589 18 61 00 35)

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Fig 32: Identifying Special Tool (124 589 02 34 00 28)

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Fig 33: Identifying Special Tool (201 589 01 63 00 35)

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Fig 34: Identifying Special Tool (126 589 08 21 00 35)

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Fig 35: Identifying Special Tool (140 589 08 21 00 35)

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Fig 36: Identifying Special Tool (140 589 00 08 00 35)

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Fig 37: Identifying Special Tool (140 589 01 09 00 35)

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Fig 38: Identifying Special Tool (001 589 66 21 00 00)

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Fig 39: Identifying Special Tool (001 589 67 21 00 00)

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Fig 40: Identifying Special Tool (001 589 74 21 00 00)

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Fig 41: Sectional View Of Rear Axle Assembly

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Dismantling 

1. Drain hypoid transmission fluid.
2. Clamp rear axle center piece in jig (050) 129 589 00 31 00 with attachment (050a) 129 589 00 31 00 part 15 and tighten bolts (arrows).
   Fig 42: Identifying Jig And Bolts

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3. Remove rear axle end cover (54) from rear axle center piece.
   Fig 43: Identifying Rear Axle End Cover

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4. Pull circlips (30a) off both connecting flanges using suitable pliers or hook 116 589 01 62 00.
   Fig 44: Identifying Circlips

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5. Pull connecting flanges (33a) out of rear axle shaft gears.
   Fig 45: Identifying Connecting Flanges

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6. Unscrew Allen bolts (27a). Pull side bearing covers (27b) out of rear axle housing and remove together with shims.

   

   Ensure that the differential does not fall out of the rear axle housing.

   Fig 46: Identifying Side Bearing Cover

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7. Remove differential (12a) from rear axle housing.
   Fig 47: Identifying Differential

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8. Pull off O-rings (25). Remove shims (26) for adjusting backlash and housing expansion, and mark together with the bearing covers (27b) for left and right sides.
   Fig 48: Identifying O-Ring, Shim And Bearing Cover

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9. Clamp side bearing covers in vice and press radial oil seal (32a) out of side bearing covers (27 and 27b) using a screwdriver.
   Fig 49: Identifying Radial Oil Seal And ABS Bearing Cover

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   Fig 50: Identifying Radial Oil Seal And ASR Bearing Cover

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10. Pull tapered roller bearing inner race (11a) out of bearing cover (27b) using puller (011) 123 589 08 33 00, and mark for left and right sides.
    Fig 51: Identifying Tapered Roller Bearing Inner Race, Bearing Cover And Puller

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11. Pull both tapered roller bearing outer races (11a) out of differential housing using puller (011a) 000 589 88 33 00 and arms (011b) 126 589 00 34 00, and mark in order to avoid confusion when reinstalling.
    NOTE: Use the thrust piece (011c) 124 589 02 34 00 for support.
    Fig 52: Identifying Tapered Roller Bearing Outer Race And Puller

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12. Slacken locking bolts (serrated bolts) (13a) and carefully press off crown wheel (47a).
    NOTE: If the crown wheel/pinion is to be reinstalled, mark the position of the crown wheel with respect to the differential housing (arrow) so that the crown wheel can be returned to the same position when reinstalling.
    Fig 53: Identifying Locking Bolts And Crown Wheel

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
13. Place pin wrench (040) 129 589 01 07 00 on propeller flange (41a). Unscrew twelve-point collared nut using 30 mm socket wrench attachment (040a) 126 589 02 09 00 and remove.
14. Mark position of propeller flange with respect to bevel drive pinion.
    Fig 54: Identifying Propeller Flange

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15. If necessary, pull propeller flange (41a) off bevel drive pinion using puller (041) 129 589 01 33 00 and remove.
    Fig 55: Identifying Propeller Flange And Puller

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16. Press radial oil seal (42a) out of rear axle housing using a suitable screwdriver or chisel.
    Fig 56: Identifying Radial Oil Seal

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17. Press oil slinger (43c) off twelve-point collared nut (43b) using a screwdriver.
    Fig 57: Identifying Oil Slinger And Twelve-Point Collared Nut

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18. Unscrew inner twelve-point collared nut using socket wrench attachment WAF 41 (043) 140 589 01 09 00 and 3/4" socket wrench attachment (043a) 140 589 00 08 00 and remove.

    

    When releasing the twelve-point collared nut, allow the socket wrench extension (043) to rest on the jig (arrow).

    Fig 58: Identifying Socket Wrench Attachment WAF 41

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19. Press bevel drive pinion (47) out of rear axle housing using two-arm puller (047) 000 589 65 33 00 and remove with tapered roller bearing inner race.
    Fig 59: Identifying Bevel Drive Pinion And Two-Arm Puller

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20. Attach removal/installation tool (038) 140 589 10 43 00 part 03 to rear axle housing. Use thrust piece (038a) 140 589 10 43 00 part 16 to pull inner tapered roller bearing outer race (46) out of rear axle housing. Remove shim.
    Fig 60: Identifying Removal/Installation Tool, Thrust Piece And Inner Tapered Roller Bearing Outer Race

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21. Use thrust piece (038b) 140 589 10 43 00 part 18 to press out outer tapered roller bearing outer race (43).
22. Unscrew removal/installation tool from rear axle housing.
    Fig 61: Identifying Thrust Piece And Outer Tapered Roller Bearing Outer Race

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23. Remove spacer sleeve (44) and contact washers (48) from bevel drive pinion.
    Fig 62: Identifying Spacer Sleeve, Contact Washers And ABS Rotor

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24. Pull ABS rotor (49) off bevel drive pinion using puller (063) 000 589 88 33 00 and arms (063a) 116 589 12 33 00, except on rear axle center pieces with ASR.
    Fig 63: Identifying ABS Rotor, Puller And Arms

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
25. Assemble pulling device 001 589 36 33 00 with extension (024c) 000 589 35 34 00 and collet chuck (024a) 140 589 02 34 00.
26. Push collet chuck (024a) of pulling device over tapered roller bearing and secure behind rollers of tapered roller bearing with clamping sleeve (024b).

    Open-end wrench WAF 55x65 140 589 00 01 00

    Fig 64: Identifying Collet Chuck And Clamping Sleeve

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27. Pull tapered roller bearing inner race off bevel drive pinion using puller (024).
    Fig 65: Identifying Puller

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    Checking 

28. Check all parts to see if they can be reinstalled. Check bearing seats on bevel drive pinion for radial run-out. Maximum radial run-out 0.02 mm  .
29. Check contact surface for radial oil seal on propeller flange. Replace propeller flange is contact surface is worn.
30. Push propeller flange onto bevel drive pinion, aligning the marks drawn earlier. Check radial run-out of propeller flange at contact surface for radial oil seal. If the radial run-out exceeds 0.06 mm, even after altering the position of the propeller flange on the splines, replace the propeller flange.
    NOTE: Each bevel drive pinion and crown wheel of a set is marked with a serial number (arrows) which is stamped on both parts. In addition, the bevel drive pinion is always marked with the specific distance (with the sign + or -) for this crown wheel/pinion that is to be set between the two gears.
    Fig 66: Identifying Serial Number On Bevel Drive Pinion And Crown Wheel

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    A data sheet must be used to calculate the gauge of the shim required to adjust the bevel drive pinion. A specimen data sheet can be found at the end of this operation number  . The measurement and calculation procedures of the example given in this data sheet are described in detail below.

    Assembling and adjusting crown wheel/pinion 

31. Press large tapered roller bearing (46) onto bevel drive pinion (47) using sleeve (047) 140 589 04 15 00 part 01. To do this, first remove inner sleeve, part 02.
    Fig 67: Identifying Large Tapered Roller Bearing, Bevel Drive Pinion And Sleeve

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
32. Press on ABS rotor (49) using sleeve (047) 140 589 04 15 00 part 1 and inner sleeve (047a) part 2, except on rear axle center pieces with ASR.
    NOTE: The number of teeth on the rotor must correspond with the rear axle ratio (see technical data).
    Fig 68: Identifying ABS Rotor And Sleeve

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
33. Screw gauge and gauge holder (056) 363 589 02 21 00 (remove magnetic stand) onto measuring base (031) 140 589 16 23 00.
34. With approx. 3 mm bias, first set gauge to "0" on gauging member (051b) 140 589 07 21 00 part 01.
    Fig 69: Identifying Gauge Holder And Gauging Member

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
35. Press outer bearing race (46) onto roller cage of bevel drive pinion (47) and add magnetic plate (020) 140 589 25 63 00. Insert bevel drive pinion (47) into measuring base (031) and measure height of bevel drive pinion with bearing and magnetic plate.
    Fig 70: Identifying Outer Bearing Race, Bevel Drive Pinion And Magnetic Plate

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
36. Read off difference between height of gauging member "B1" and height of bevelled end of drive pinion "B" and enter the value calculated (e.g. 1.46 mm) beside section 1 in the data sheet.
37. Enter fundamental deviation "a" of bevel drive pinion (see arrow, + or -) beside section 2 (e.g. - 0.04 mm) in the data sheet.
38. According to the sign of the number on the bevel drive pinion, either add (+) or subtract (-) values from sections 1 and 2.
    Fig 71: Identifying Number On Bevel Drive Pinion

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39. Insert gauging member (051b) 140 589 07 21 00 part 01 into rear axle housing and screw together with retaining piece 140 589 07 21 00 part 02.
Fig 72: Identifying Gauging Member
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40. Install gauge with gauge holder (030) 111 589 08 23 00 in adjustment gauge (035) 115 589 05 21 00 and set to "0" with 3 mm  bias.
    Fig 73: Identifying Gauge Holder

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
41. Clean contact surfaces of bearing covers on sides of rear axle housing.
42. Insert measuring bracket (030a) 116 589 01 21 00 part 01 together with gauge holder (030) and gauge into left-hand bore in rear axle housing and screw in place.
43. Read off difference between set gauge distance and end face of gauging member, and enter beside section 3 in either the positive or negative direction (e.g. - 0.55 measured, therefore in negative direction).
    Fig 74: Identifying Measuring Bracket And Gauge Holder

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    NOTE: The direction positive (+) or negative (-) refers to the direction of rotation of the gauge needle. Any counterclockwise deviation from the zero position is in the negative direction  , clockwise is the positive direction  .
    Fig 75: [Identifying Gauge Setting Distance]

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
44. Add (+) or subtract (-) the subtotal from sections 1 and 2 with the value from section 3. The result obtained gives the gauge of the shim.

    Example  :

    Fig 76: [Example For Calculation Gauge Of Shim]

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45. Remove measuring bracket and gauging member from rear axle housing.
46. Insert shim (45) of calculated gauge "S" into rear axle housing (see example).
    NOTE: Only tempered shims must be used. Shims are available in various gauges (see technical data). If necessary, a shim should be ground down as required.
    Fig 77: Identifying Shim

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
47. Pull outer races of front (43) and rear (46) tapered roller bearings into rear axle housing using puller (060a-d) 140 589 01 43 00.

    

    Ensure that the outer races do not tilt during installation.

    Fig 78: Identifying Front/Rear Tapered Roller Bearing Outer Races And Puller

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
48. Add one contact washer (48) to each side of new  spacer sleeve (44) and push onto bevel drive pinion.
    Fig 79: Identifying Contact Washer And Spacer Sleeve

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
49. Install bevel drive pinion in rear axle housing and support with removal/installation tool (038) 140 589 10 43 00 by carefully screwing in threaded spindle by hand as far as end face of bevel drive pinion.
    Fig 80: Identifying Removal/Installation Tool

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
50. Push tapered roller bearing inner race (43) onto bevel drive pinion and press in with sleeve (047) 140 589 04 15 00.
    Fig 81: Identifying Tapered Roller Bearing Inner Race And Sleeve

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
51. Screw on new inner twelve-point collared nut (43b).

    

    Coat the contact collar of the twelve-point collared nut with molycote grease.

    Fig 82: Identifying Inner Twelve-Point Collared Nut

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
52. Push socket wrench attachment WAF 41 (043) 140 589 01 09 00 and 3/4" socket wrench attachment (043a) 140 589 00 08 00 onto bevel drive pinion.
    Fig 83: Identifying Socket Wrench Attachment WAF 41 And Socket Wrench Attachment

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
53. Carefully  tighten twelve-point collared nut using torque wrench 001 589 74 21 00 until the specified friction torque is attained (see table "Friction torque for bevel drive pinion bearing").
    Fig 84: Identifying Torque Wrench 001 589 74 21 00

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    

    When tightening the twelve-point collared nut, turn the bevel drive pinion several times and gently tap the rear axle housing to ensure that the tapered rollers properly engage in their tracks.

54. Remove removal/installation tool with socket wrench attachment WAF 41 from rear axle housing.
55. To check installation, attach torque meter (018) 001 589 48 21 00 with adapter (019) 100 589 02 59 00 to 3/4" socket wrench attachment (043a) 140 589 00 08 00 and crank bevel drive pinion.

    

    To measure the friction torque, the bevel drive pinion must be cranked by hand at approx. 50-60 revs/min.

    Fig 85: Identifying Torque Meter With Adapter And Socket Wrench Attachment

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    NOTE: The tapered roller bearings (43 and 46) of the bevel drive pinion (47) must be installed with a certain bias. This permanent bias is obtained by compressing the spacer sleeve (44) located between the inner bearing race of the front tapered roller bearing and the bevel drive pinion while tightening the twelve-point collared nut (43b).
    Fig 86: Identifying Tapered Roller Bearings, Bevel Drive Pinion, Spacer Sleeve And Twelve-Point Collared Nut

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    If the friction torque when the bevel drive pinion slips is too low (i.e. if the bias is insufficient), the twelve-point collared nut (43b) should be tightened further slightly. If the specified friction torque is exceeded, the bevel drive pinion must be removed again and a new  spacer sleeve (44) installed. The friction torque must never be reduced by slackening the twelve-point collared nut  , or the bias of the tapered roller bearings will be insufficient. This would result in play in the bevel drive pinion during driving and possible noises in the rear axle drive unit.

56. Again install measuring equipment (040) 116 589 01 21 00 part 01, together with gauge holder (030) 111 589 08 23 00 and gauge, in left-hand bore in rear axle housing to check the setting. Place magnetic plate (020) 140 589 25 63 00 on end face of bevel drive pinion to measure adjustment distance "A".
    NOTE: The deviation of the crown wheel/pinion in this example is - 0.04 mm from the basic dimension in the negative direction and corresponds to the value stamped on the end face of the bevel drive pinion.
    Fig 87: Identifying Gauge Holder And Magnetic Plate

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    The permissible fundamental deviation of the adjustment distance "A" must not be exceeded by more than 0.01 mm in the positive and 0.02 mm in the negative direction.

    If the deviation is larger, the installed shim must be re-ground or a new shim of the corresponding gauge must be installed. It is absolutely essential, however, that a new spacer sleeve  for the tapered roller bearings be installed.

    Fig 88: Identifying Deviation Of Crown Wheel/Pinion

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
57. Remove measuring equipment, magnetic plate and gauge with holder from rear axle housing.
58. Caulk twelve-point collared nut (43b) into one of the two grooves in the bevel drive pinion so that there is no gap between the groove and locking tab (detail, top left).

    

    Do not deal any strong blows in the axial direction.

    Fig 89: Identifying Twelve-Point Collared Nut

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
59. Push on new oil slinger (43c). Press onto collar of twelve-point nut using drift (042a) 140 589 02 15 00.
    Fig 90: Identifying Oil Slinger

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 91: Identifying Tapered Roller Bearings, Bevel Drive Pinion And Spacer Sleeve

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
60. Coat lip of rubber/metal radial oil seal (42a) with hypoid transmission fluid and press into rear axle housing using drift (042a) 140 589 02 15 00.
    Fig 92: Identifying Rubber/Metal Radial Oil Seal And Drift

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
61. Replace O-ring (41b) in 4-arm propeller flange.
62. Push propeller flange onto bevel drive pinion noting the alignment marks made earlier on propeller flange and bevel drive pinion.
    Fig 93: Identifying O-Ring

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
63. Screw on new twelve-point collared nut. Push pin wrench (040) 129 589 01 07 00 and 30 mm socket wrench attachment (040a) 126 589 02 09 00 onto propeller flange (41a) and tighten twelve-point collared nut to 120-130 Nm.
    Fig 94: Identifying Pin Wrench, Socket Wrench Attachment And Propeller Flange

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
64. Caulk twelve-point collared nut (40a) into one of the two grooves in the bevel drive pinion so that there is no gap between the groove and locking tab (detail, top left).

    

    Do not deal any strong blows in the axial direction.

    Fig 95: Identifying Twelve-Point Collared Nut

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
65. Press tapered roller bearing inner race (11a) into side bearing covers (27 and 27b) using drift (011a) 140 589 09 15 00.
    Fig 96: Identifying Tapered Roller Bearing Inner Race, Side Bearing Covers And Drift (Arrangement With ABS)

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 97: Identifying Side Bearing Cover And Drift (Arrangement With ASR)

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
66. Press in radial oil seal (32a) using drift (032a) 140 589 03 15 00. To do this, lay bearing cover (27b) on removal/installation tool (034a) 129 589 02 43 00 part 01.
    Fig 98: Identifying Radial Oil Seal, Drift, Bearing Cover And Removal/Installation Tool

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
67. Place previously removed shims (26) on bearing covers (27b) and insert new O-rings (25) into grooves in bearing cover.
    Fig 99: Identifying Shim, Bearing Cover And O-Ring

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Adjusting backlash 

    NOTE: The backlash of the crown wheel/pinion and the necessary bias in the tapered roller bearings for the differential are adjusted by installing shims between the bearing covers and the rear axle housing. The shims are available in various gauges. To install, first reinstall the previously removed bearing cover and shims on the appropriate side to obtain a provisional basic setting.
68. Dismantle and assemble differential (35-560) .
69. Carefully clean crown wheel and seat on differential housing. Heat crown wheel (47a) to 75-85°C and place on differential housing. If appropriate, note the alignment marks made earlier on the crown wheel and differential housing (arrow).

    If the crown wheel will not go on the differential housing, ease it into place by tapping with a plastic mallet.

    Fig 100: Identifying Crown Wheel

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    

    When installing a new differential housing or if using new crown wheel bolts, note the length of the crown wheel bolts. For differential housings with 8 mm thick  contact flange (distance "B"), use crown wheel bolts 20 mm long  .

    Fig 101: Identifying Differential Housing Contact Flange Thickness

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
70. Tighten new serrated locking bolts (13a) to 140 Nm in a cross-wise pattern. Torque wrench 001 589 67 21 00.

    

    Always replace crown wheel bolts when they have been used once.

    Fig 102: Identifying Locking Bolts And Crown Wheel

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
71. Press tapered roller bearing outer race (11a) into differential housing (12a) using drift (011a) 140 589 09 15 00.
    Fig 103: Identifying Tapered Roller Bearing Outer Race, Differential Housing And Drift

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
72. Lightly coat circumference of O-rings and bearing cover (27a) with hypoid transmission fluid.
73. Insert differential into rear axle housing and push in both side bearing covers (27a) as far as they will go.

    

    Do not damage the O-rings when installing the bearing covers.

    Fig 104: Identifying Side Bearing Covers

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    

    Not installed position of the side bearing covers. The ABS bearing covers are marked with the word

    "UNTEN"  (= down). ASR bearing covers must be installed with the speed sensor connection pointing upwards. This information refers to the installed position of the rear axle center piece in the vehicle.

    Fig 105: Identifying Side Bearing Cover Installation Position (Arrangement With ABS)

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    NOTE: If the side bearing covers stick in the bore in the rear axle housing, ease them into place by tapping with a plastic mallet (arrows).
    Fig 106: Identifying Side Bearing Cover Installation Position (Arrangement With ASR)

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
74. Screw contact blocks (050a) 201 589 01 63 00 for contact arm (050) 126 589 08 21 00 to left and right sides of sealing surface on rear axle housing.
    Fig 107: Identifying Contact Blocks For Contact Arm

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
75. Place contact arm for measuring housing expansion and gauge on contact blocks and set gauge to "0" with approx. 3 mm bias.
    Fig 108: Identifying Contact Blocks And Contact Arm

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
76. Screw in all Allen bolts (27a) on side bearing covers and tighten to 20 Nm. Torque wrench 001 589 66 21 00.
77. Use contact arm again. The required expansion (spread) of the rear axle housing, and thus the correct bias for the tapered roller bearings on the differential, is obtained when the expansion measures between 0.15 and 0.20 mm  .
    Fig 109: Identifying Contact Arm

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
78. Install backlash meter (037) 140 589 08 21 00 with bushing in left-hand bore in differential housing and secure.
79. By moving the gauge holder or the crown wheel, measure the backlash at four points referred to the circumference of the crown wheel. The smallest measurement applies. The backlash must measure 0.08 -0.14 mm  . During each measurement, hold the bevel drive pinion securely by the propeller flange.
    Fig 110: Identifying Backlash Meter

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    NOTE: The adjustment of the tapered roller bearings and the crown wheel/pinion is correct when both the spread (expansion) of the rear axle housing and the backlash are within the nominal ranges. If these values are not attained, the adjustment must be repeated using thicker or thinner shims as required (see technical data).

    Example 1 

    If the backlash is correct but the expansion of the rear axle housing is too small, then shims of equally smaller gauge must be installed on both side bearing covers.

    Example 2 

    If the expansion is correct but the backlash is excessive, then a shim which is thicker by the missing amount must be installed on the lefthand side, and a shim which is thinner by the same amount on the right-hand side. If the backlash is insufficient, proceed in the reverse sequence.

80. Remove contact blocks.
81. Pull deep-groove ball bearing from connecting flange (33a). Use pulling device 001 589 36 33 00, collet chuck 140 589 00 34 00 and open-end wrench WAF 55x65 mm 140 589 00 01 00.
    Fig 111: Identifying Connecting Flange

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
82. Press deep-groove ball bearing (33c) all the way onto flange using a suitable tube (033c).
    Fig 112: Identifying Deep-Groove Ball Bearing And Tube

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
83. Push left and right connecting flanges (33a) into rear axle shaft gear.
    Fig 113: Identifying Connecting Flanges

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
84. Press new circlip (30a) of same gauge as that previously installed between connecting flange and rear axle shaft gear.
85. Check axial play between connecting flange and rear axle shaft gear. There must be no perceptible play. The circlip should still be free to rotate in the groove. If necessary, install a thicker or thinner circlip as required (see technical data).

    

    Replace the circlip if it has been used once  .

    Fig 114: Identifying Circlip

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
86. Clean sealing surfaces on rear axle end cover (54) and rear axle housing, and coat with sealant.
87. Install rear axle end cover. Tightening torque of multi-point Allen bolts 55 Nm. Torque wrench 001 589 66 21 00
88. Remove rear axle center piece from the jig.
    Fig 115: Identifying Rear Axle End Cover

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Rear axle center piece with ASR 

89. Measure distance "a" between contact surface of speed sensor and head dia. of ASR rotor (see detail) using commercially available depth gauge (033d). Determine gauge of shim from table (see technical data) and stick appropriate shim onto contact surface with self-adhesive paper.
    Fig 116: Identifying Depth Gauge

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
90. Fill with hypoid transmission fluid up to lower edge of oil filler bore (for oil type and capacity, see technical data). Tightening torque of screw plug 50 Nm.
91. Replace breather (55) on rear axle housing. Tightening torque 30 Nm.
    Fig 117: Identifying Breather On Rear Axle Housing

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.