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Remove/install rear axle differential - AR35.31-P-0520A: Notes

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Rear axle differential dia. 198 in MODEL 140 

Rear axle differential dia. 210 in MODEL 140 

Fig 1: Identifying Rear Axle Differential Components
G05437461Courtesy 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 columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
1.1 Relieve the pressure in the hydraulic unit (83) Vehicles with ASD code 211 and pressure reservoir up to 05/92
IMPORTANTInstallation:  Vehicles with ASD code
211: ↓		 AR35.31-P-0520-01A 
    Bleed ASD hydraulic system AR35.41-P-0519A 
2 Remove complete exhaust system Engine 104 AR49.10-P-7000D
    Engine 119 AR49.10-P-7000E
    Engine 120 AR49.10-P-7000F
    Engine 603 ra49006027000x
    Engine 606 AR49.10-P-7000H
3 Remove exhaust heat shield (105c)    
4.1 Loosen propeller shaft clamping nut (106c) SPECIAL TOOL Model 140.02/03/1 up to 06/95, model 140.04 up to 03/93, model 140.050/051 up to 11/91 Figure
    IMPORTANTInstallation:  Tighten propeller shaft clamping nut AR41.10-P-0050-12DA
5 Remove bolts for propeller shaft intermediate bearing (106a). IMPORTANTInstallation:  ↓  
    Tighten bolts in propeller shaft intermediate bearing AR41.10-P-0050-13DA
6 Detach rear propeller shaft from rear axle center assembly IMPORTANT Flexible disk remains on propeller shaft.  
    IMPORTANTInstallation:  Connect rear propeller shaft to rear axle differential AR41.10-P-0050-04DA
    TORQUE SPECIFICATION Replace nuts (106e). *BA41.10-P-1002-01A 
7 Loosen fitting sleeves on flexible couplings. IMPORTANT Tie up propeller shaft to one side. AR41.10-P-0050-09DA
REFER TO SHOP-MADE TOOLS Drift for loosening fitting sleeves in flex disks.   WF58.50-P-4110-01A
8 Remove rear axle shafts (37) from connecting flange IMPORTANT Move rear axle shaft so that is roughly horizontal and then push together. Remove rear axle shaft from connecting flange diagonally downward and tie to rear spring.
NOTESInstallation:  Replace self-locking internal polygon or hexagon socket head screws and shims.
Lightly oil bolts at thread and bolt head contact surface.		  
    TORQUE SPECIFICATION *BA35.30-P-1002-01A 
9.1 Detach cover for fuel pump assembly (115c) Vehicles with gasoline engines AP47.20-P-0780-03DA
10 Detach connector (a)    
11 Support rear axle center assembly (50) SPECIAL TOOL Figure
12 Remove bolts (54b) on extension bracket TORQUE SPECIFICATION *BA35.10-P-1002-02A 
REFER TO COMPONENT MODIFICATIONS Stiffer spring control arm rubber mounts   BT35.10-P-0003-01A 
13 Remove front center assembly mounting IMPORTANTInstallation:  ↓  
    Install front differential mount AR35.10-P-0050-01A 
14.1 Detach hydraulic line (HS) Vehicles with ASD [automatic locking differential] (Code 211)  
15 Lower and remove rear axle center assembly (50)    
16.1 Detach rpm sensor (d) with bracket (98) Vehicles with ABS and ASD up to 06/94
IMPORTANTInstallation:  Replace O-rings.		  
17.1 Detach rpm sensor (b, c) Vehicles with ABS and ASD up to 06/94
IMPORTANTInstallation:  Replace O-rings.		  
18 Replace breather of rear axle center assembly TORQUE SPECIFICATION *BA35.31-P-1005-02A 
19 Install in the reverse order    
20 Check oil level in rear axle differential and correct if necessary IMPORTANT Mixing of old universal hypoid gear oil and the new FE hypoid gear oil should be avoided due to the better fuel economy. AR35.31-P-0520-03A
    FLUID SPECIFICATION Filling capacity of rear differential assembly *BF35.31-P-1001-01A 
    Cleaning spray, Loctite 7063 (150ml) *BR00.45-Z-1046-04A 
    Sealant, Omnifit 100H (50 g) *BR00.45-Z-1061-01A 
    TORQUE SPECIFICATION Oil filler plug *BA35.31-P-1002-02A 
REFER TO COMPONENT MODIFICATIONS Oil filler/drain screw on rear axle differential modified Phased in as of 19.01.04 BT35.31-P-0015-01A
TORQUE SPECIFICATION REAR AXLE CARRIER

Number Designation Model 140
BA35.10-P-1003-01A Self-locking nut, rear axle differential at front to rear axle carrier Nm 45
TORQUE SPECIFICATION EXTENSION BRACKET FOR REAR AXLE CENTER ASSEMBLY

Number Designation Model 140
BA35.10-P-1002-02A Bolt, extension bracket to rear axle center assembly Yellow Nm 80
silver or blue Nm 70
TORQUE SPECIFICATION REAR AXLE SHAFT

Number Designation Model 140
BA35.30-P-1002-01A Self-locking bolt, rear axle shaft to connecting flange (thread and bolt head contact surface oiled) M10 Nm 70
M12 Nm 100
TORQUE SPECIFICATION REAR AXLE CENTER ASSEMBLY HOUSING

Number Designation Model 140
BA35.31-P-1002-02A Oil filler screw, rear axle differential Nm 50
BA35.31-P-1005-02A Breather, rear axle center assembly Nm 30
TORQUE SPECIFICATION DRIVESHAFT

Number Designation Model 140
BA41.10-P-1002-01A Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential. M10 Nm -
M12 Nm 60
BA41.10-P-1003-01A Clamping nut of propeller shaft Nm 40
TORQUE SPECIFICATION PROPELLER SHAFT INTERMEDIATE BEARING

Number Designation Model 140
BA41.40-P-1001-01A Bolt driveshaft center bearing to frame Bolt with washer Nm 25
Bolt with collar and self-centering tip Nm 30
Bolt with collar and without self-centering tip Nm -
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model Series 140.02/03 without (code 211) ASD up to 05/94 Model 140.02/03 as of 06/94 Model Series 140.02/03 with (code 211) ASD up to 05/94
BF35.31-P-1001-01A Filling capacity Rear axle differential Liters 1,3 1,1 1,3
Specifications for Operating Fluids Sheet BB00.40-P-0235-00A BB00.40-P-0235-00A -
Sheet BB00.40-P-0235-07A BB00.40-P-0235-07A BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model Series 140.04/06 Model 140.05/07 Model Series 140.1 without (Code 211) ASD
BF35.31-P-1001-01A Filling capacity Rear axle differential Liters 1,3 1,4 1,3
Specifications for Operating Fluids Sheet BB00.40-P-0235-00A BB00.40-P-0235-00A BB00.40-P-0235-00A
Sheet BB00.40-P-0235-07A - BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model Series 140.1 with (Code 211) ASD
BF35.31-P-1001-01A Filling capacity Rear axle differential Liters 1,3
Specifications for Operating Fluids Sheet -
Sheet BB00.40-P-0235-07A
Fig 2: Identifying Open End Wrench (126 589 00 01 00)
G05437462Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Assembly Attachment (140 589 01 62 00)
G05437463Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1061-01A Sealant, Omnifit 100H (50 g) A 002 989 23 71
BR00.45-Z-1046-04A Cleaning spray, Loctite 7063 (150ml) A 001 986 71 71 10
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