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Remove/install inside CV joint or rubber boots on rear axle shaft - AR35.30-P-0660A: Notes

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MODEL 129, 140, 170, 202, 203.006 /016 /206 /216 /706, 208, 209, 210, 215, 220 up to 30.9.99 

MODEL 203.004 with CODE (450) taxi version 

Fig 1: Identifying Inside CV Joint Or Rubber Boots Components On Rear Axle Shaft - MODEL 202
G04713459Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/install     
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between the four pillars of the hoist and position the four support plates at the hoist mounting points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
1 Raise vehicle with lifting platform    
2 Remove rear wheel    
REFER TO MAINTENANCE Remove and install wheels   AP40.10-P-4050Z
3 Remove rear axle shaft (37a) Models 129, 140, 170, 202, 203, 208, 209, 210 AR35.30-P-0620A 
    Model 215, 220 AR35.30-P-0620I
REFER TO COMPONENT MODIFICATIONS Rear axle shaft modified from solid shaft to hollow shaft MODEL 215, 220 as of 01.10.99 BT35.30-P-0007-01I
4 Detach hose clamps (37k) IMPORTANTInstallation:  Replace hose clamps (37k), observing the width of the hose clamps.  
REFER TO COMPONENT MODIFICATIONS Rear axle shaft rubber boot and hose clamp modified Models 129, 140, 202 BT35.30-P-0003-01A 
5 Detach end cover (37h) and cup seal (37i) from inner joint ring (37c) IMPORTANTInstallation:  Replace end cover (37h).  
    IMPORTANTInstallation:  Attach end cover (37h) and cup seal (37i) to inner joint ring (37c). AR35.30-P-0660-01A 
    FLUID SPECIFICATION Model 129, 140, 170, 202, 208, 209, 210, 215, 220 *BF35.30-P-1001-01A 
    FLUID SPECIFICATION Model 203 *BF35.30-P-1001-01D 
    Sealing compound *BR00.45-Z-1008-01A 
    Sealing compound *BR00.45-Z-1009-01A 
    Sealing compound *BR00.45-Z-1010-01A 
6 Remove circlip (37g) IMPORTANTInstallation:  Replace circlip (37g).  
7 Detach rubber boot (37l) with cup seal (37i) IMPORTANTInstallation:  Fit a suitable assembly sleeve on the splined profile of the rear axle shaft (37a) in order to prevent damage to the splined profile.  
8 Press inner constant velocity joint off of rear axle shaft IMPORTANT The inner constant velocity joint consists of the inner joint ring (37c), the joint hub (37d), the balls (37e) and the ball retainer (37f). AR35.30-P-0660-02A 
REFER TO SHOP-MADE TOOLS Shell halves (2 ea.) for pressing off and caulking the inner constant velocity joint.   WF58.50-P-3530-01A
    SPECIAL TOOL Clamping jaws Figure
    SPECIAL TOOL Clamping jaws Figure
    SPECIAL TOOL Drift Figure
9 Detach rubber boot (37m) 0IMPORTANT The rubber boot (37m) of the rear axle shaft (37a) on the outer joint ring (37b) can only be replaced after disassembling the inner constant velocity joint because the outer constant velocity joint cannot be disassembled.
IMPORTANTInstallation:  Scrape off the grease inside the rubber boot (37m) and use it to fill the outer constant velocity joint; replace grease if necessary.		  
    FLUID SPECIFICATION Model 129, 140, 170, 202, 208, 209, 210, 215, 220 *BF35.30-P-1002-01A 
    FLUID SPECIFICATION Model 203 *BF35.30-P-1002-01D 
    IMPORTANTInstallation:  To pull on the rubber boot (37m) fit a suitable assembly sleeve on the splined profile of the rear axle shaft (37a).  
INSPECT Checking     
10 Disassemble inner constant velocity joint and check for wear and damage IMPORTANT The inner constant velocity joint consists of the inner joint ring (37c), the joint hub (37d), the balls (37e) and the ball retainer (37f). AR35.30-P-0660-03A 
REFER TO COMPONENT MODIFICATIONS Rear axle shaft has been reinforced at ball retainer Model 129 BT35.30-P-0001-01A
11 Install in the reverse order    
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 129.058/059/060/061/063/064 Model 129.066/067/068/076 Model 140.02/03/1
BF35.30-P-1001-01A Filling capacity Inner constant-velocity joint g 120 150 120
BF35.30-P-1002-01A Filling capacity Outside constant velocity joint g 120 120 120
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 140.04/05/06/07 Model 170.435/444 Model 170.445/447/449/465/466
BF35.30-P-1001-01A Filling capacity Inner constant-velocity joint g 100 120 100
BF35.30-P-1002-01A Filling capacity Outside constant velocity joint g 100 120 100
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 202.018/020/022/023/025/026/078/080/081/082/083/086/087/088/120/121/122/125/180/182 Model 202.024/028/029/033/085/089/093/128/133/134/188/193/194 Model 208.335/335/344/435/444/ 445
BF35.30-P-1001-01A Filling capacity Inner constant-velocity joint g 150 100 100
BF35.30-P-1002-01A Filling capacity Outside constant velocity joint g 120 100 100
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 208.347/347/348/370/374/ 447/448/ 448/465 Model 208.474 Model 209.316 with transmission 716 Model 209.365/465
BF35.30-P-1001-01A Filling capacity Inner constant-velocity joint g 120 150 120
BF35.30-P-1002-01A Filling capacity Outside constant velocity joint g 120 130 120
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 209.316 with transmission 722 Model 209.341/342/343/361 Model 209.441/442
BF35.30-P-1001-01A Filling capacity Inner constant-velocity joint g 120 100 100
BF35.30-P-1002-01A Filling capacity Outside constant velocity joint g 140 100 120
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 209.372/375/376/377/472/475/476/477 Model 210.003/004/010/035/037/048/061/062/210/235/237/248/261/262/610 Model 210.006/007/015/016/017/020/025/026/045/053/055/063/065/07/08/206/215/216/217/225/226/245/263/265/27/28/606/616/617/663
BF35.30-P-1001-01A Filling capacity Inner constant-velocity joint g 150 100 120
BF35.30-P-1002-01A Filling capacity Outside constant velocity joint g 140 100 120
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 215.375/376/378 Model 220.026/063/065/067/070/083/084/087/126/163/165/167/170/183/184/187 Model 220.025/028/073/075/125/128/173/175/875/878
BF35.30-P-1001-01A Filling capacity Inner constant-velocity joint g 150 120 150
BF35.30-P-1002-01A Filling capacity Outside constant velocity joint g 120 120 120
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 203.004/204 with code 450, inserted axle shaft Model 203.004/204 with code 450, screwed axle shaft Model 203.006/206/706 with transmission 722
BF35.30-P-1001-01D Filling capacity Inner constant-velocity joint g 120 120 120
BF35.30-P-1002-01D Filling capacity Outside constant velocity joint g 140 120 120
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 203.006/206/706 with screwed rear axle shaft Model 203.006/206/706 with inserted axle shaft, except transmission 722 Model 203.008/016/20 8/216/708 with transmission 722, model 203.007/207 with transmission 722 and code 450
BF35.30-P-1001-01D Filling capacity Inner constant-velocity joint g 120 120 105
BF35.30-P-1002-01D Filling capacity Outside constant velocity joint g 120 140 120
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 203.016/216 except trans. 722
BF35.30-P-1001-01D Filling capacity Inner constant-velocity joint g 150
BF35.30-P-1002-01D Filling capacity Outside constant velocity joint g 130
Fig 2: Identifying Clamping Jaws (116 589 11 31 00)
G04713460Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Clamping Jaws (220 589 02 31 00)
G04713461Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Drift (116 589 15 15 00)
G04713462Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1008-01A Curil sealing compound ElringKlinger AG
Max-Eyth-Strasse 2
72581 Dettingen/Ems
Germany
Tel. +49 7123 724-0
Fax +49 7123 724 9006
www.elringklinger.de
BR00.45-Z-1010-01A Sealant A 001 989 25 20
BR00.45-Z-1009-01A Sealant A 001 989 89 20
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