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Replace radial sealing ring at drive pinion gear (with rear axle differential installed) - AR35.31-P-0530A: Notes

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Rear axle differential dia. 198 in MODEL 140 

Rear axle differential dia. 210 in MODEL 140 

Rear axle differential dia. 210 in MODEL 140 

rear differential assembly reinforced 

Fig 1: Identifying Rear Differential Assembly
G05437472Courtesy 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 lifting platform and position the four support plates at 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 Raise vehicle    
2 Drain oil from rear axle differential   AR35.31-P-0520-06A
    Cleaning spray, Loctite 7063 (150ml) *BR00.45-Z-1046-04A 
    Sealant, Omnifit 100H (50 g) *BR00.45-Z-1061-01A 
    TORQUE SPECIFICATION Oil drain screw *BA35.31-P-1003-02A 
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
3 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
4 Remove exhaust shielding plates (105c, 105e)    
5.1 Detach cover (115c) Vehicles with gasoline engine  
REFER TO MAINTENANCE Detach cover for fuel pump assembly   AP47.20-P-0780-03DA
6 Remove bracket for safety belt anchorage (127). IMPORTANTInstallation:  ↓  
    Install bracket for seat belt anchorage AR91.40-P-0502-02DA
    TORQUE SPECIFICATION *BA91.40-P-1001-01B 
7 Detach rear axle shafts (37) from the connecting flanges Model 140.02/03/04/06/1
IMPORTANT Move the rear axle shaft into approximately the horizontal position and push together.
Remove rear axle shaft from connecting flanges at a downward angle and tie up at rear springs.
NOTESInstallation:  Replace self-locking multipoint or hexagon socket bolts and washers. Lightly oil bolts at thread and bolt head contact surface.		  
    TORQUE SPECIFICATION *BA35.30-P-1002-01A 
8.1 Loosen propeller shaft clamping nut (106c) Models 140.02/03/1 up to 06/95, model 140.04 up to 03/93, model 140.050/051 up to 11/91  
    SPECIAL TOOL Open-end wrench Figure
    IMPORTANTInstallation:  ↓  
    Tighten propeller shaft clamping nut AR41.10-P-0050-12DA
    SPECIAL TOOL Open-end wrench Figure
    TORQUE SPECIFICATION *BA41.10-P-1003-01A 
9 Detach propeller shaft intermediate bearing (106a) IMPORTANTInstallation:  ↓  
    Tighten bolts in propeller shaft intermediate bearing AR41.10-P-0050-13DA
    TORQUE SPECIFICATION *BA41.40-P-1001-01A 
10 Remove rear propeller shaft assembly (106) from rear axle differential. IMPORTANT Flexible disk remains on propeller shaft.  
    IMPORTANTInstallation:  ↓  
    Mount rear propeller shaft to rear axle center assembly AR41.10-P-0050-04DA
    TORQUE SPECIFICATION *BA41.10-P-1002-01A 
11 Loosen fitting sleeves on flexible couplings. 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
12 Separate front and rear driveshafts (106) IMPORTANTInstallation:  Coat splines on shaft with extended-duty grease: ↓  
REFER TO CAPACITIES & SPECIFICATIONS   Long-life grease (NLGI grade 2) BB00.40-P-0266-02A
    Connect sections of propeller shaft AR41.10-P-0050-05DA
MEASURING Measure     
13.1 Measure and note down total friction torque of drive pinion Model 140.02/03/04/06/1 AR35.31-P-0530-04A 
    SPECIAL TOOL Torque meter Figure
    SPECIAL TOOL Socket Figure
    SPECIAL TOOL Connection piece Figure
    41 mm socket wrench bit, hexagon, 3/4 inch square  
14.1 Loosen and remove twelve-point collar nut or hexagon collar nut (40) Model 140.02/03/04/06/1  
    IMPORTANT Do not remove the collar protection when slackening twelve-point or hexagon collar nut.  
    SPECIAL TOOL Pin wrench Fig 4
    SPECIAL TOOL Socket wrench bit for: Figure
    Models 140.02/03 up to 31.05.94 and 140.04/06/1  
    IMPORTANT Observe technical modifications: ↓  
REFER TO COMPONENT MODIFICATIONS   Rear axle differential dia. 198 mm BT35.31-P-9406-01A 
    Socket 41 mm hexagon 3/4 Inch square for: Model 140.02/03 as of 01.06.94  
    IMPORTANT For better control when loosening the hexagon collar nut, press a shop-made bush into the commercially available socket wrench bit: ↓  
REFER TO SHOP-MADE TOOLS   Pressing bush for wrench socket WF58.50-P-3531-02A
    NOTESInstallation:  Replace twelve-point or hexagon collar nut and tighten in stages until the previously measured friction torque  is obtained.  
    TORQUE SPECIFICATION Observe minimum tightening torque; if necessary if tightening torque is not achieved: ↓ *BA35.31-P-1001-01A 
    Replace elastic spacer sleeve, see Disassembling and assembling rear differential assembly, adjusting gear set: ↓  
    Rear axle differential dia. 198 mm AR35.31-P-0550A 
    Rear axle center assembly ø 210 mm AR35.31-P-0550D 
    IMPORTANTInstallation:  ↓  
    Secure twelve-point and hexagon collar nut on drive pinion joint flange AR35.31-P-0530-01B 
REFER TO SHOP-MADE TOOLS   Chisel for securing collar nut on joint flange WF58.50-P-3531-01A
14.2 Slacken and unscrew twelve-point collar nut (40a) Model 140.05/07  
    IMPORTANT Do no remove collar protection when loosening twelve-point collar nut.  
    SPECIAL TOOL Pin wrench Fig 4
    SPECIAL TOOL Socket Figure
    TORQUE SPECIFICATIONNOTESInstallation:  Replace twelve-point collar nut. *BA35.31-P-1001-01A 
    IMPORTANT Secure twelve-point collar nut on drive pinion joint flange AR35.31-P-0530-01A 
REFER TO SHOP-MADE TOOLS   Chisel for securing collar nut on joint flange WF58.50-P-3531-01A
15 Pull off joint flange (41, 41a) IMPORTANT Use SPECIAL TOOL puller if necessary: ↓  
    SPECIAL TOOL Puller Fig 6
    IMPORTANTInstallation:  On model 140.05/07:  
    Replace O-ring (41b).  
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified As of 01.04.98 on model 140.02/03 up to 31.05.94 and model 140.04/06/1 BT35.31-P-0012-01A 
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified As of 15.01.02 with model 140.02/03 with rear axle differential dia. 198 mm BT35.31-P-0012-01C
16.1 Press out radial sealing ring (42) using a suitable tool Model 140.02/03/04/06/1  
    NOTES Model 140.02/03/04/1 up to 13.02.94: When pressing out a retaining lug of the pressure plate (43a) may fracture, remove if necessary.  
    IMPORTANT Observe technical modifications: ↓  
REFER TO COMPONENT MODIFICATIONS   Integrated thrust washer on tapered roller bearing inner race BT35.31-P-9402-01A 
    IMPORTANTInstallation:  Replace radial sealing ring and coat sealing lip with universal hypoid gear oil: ↓  
REFER TO CAPACITIES & SPECIFICATIONS   Universal hypoid transmission fluid BB00.40-P-0235-07A
    SPECIAL TOOL Drift for pressing in the previous radial sealing ring version for: Fig 10
    Model 140.02/03 as of 01.06.94  
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified As of 15.01.02 with model 140.02/0 rear axle differential dia. 198 mm BT35.31-P-0012-01C
    SPECIAL TOOL Drift for pressing in the new radial sealing ring version for: Fig 11
    Model 140.02/03 as of 01.06.94  
    SPECIAL TOOL Drift for pressing in for: Fig 7
    Model 140.02/03 up to 31.05.94 and model 140.04/06/1  
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified As of 01.04.98 on model 140.02/03 up to 31.05.94 and model 140.04/06/1 BT35.31-P-0012-01A 
16.2 Press out radial sealing ring (42a) using a suitable tool Model 140.05/07  
    IMPORTANTInstallation:  Replace radial sealing ring and coat sealing lip with universal hypoid gear oil: ↓  
REFER TO CAPACITIES & SPECIFICATIONS   Universal hypoid transmission fluid BB00.40-P-0235-07A
    SPECIAL TOOL Drift for pushing in Figure
17.1 Remove thrust washer (43a) Model 140.02/03/04/1 up to 13.02.94  
    IMPORTANTInstallation:  Always replace the thrust washer: ↓  
    Replace drive pinion thrust washer AR35.31-P-0530-02A 
17.2 Check oil slinger disk (43c) SPECIAL TOOL Model 140.05/07 AR35.31-P-0530-03A 
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 axle differential *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 screw for rear axle differential *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 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 DIFFERENTIAL GEAR SET

Number Designation Model 140.02/03/04/06/1 Model 140.05/07
BA35.31-P-1001-01A Collar nut, joint flange to drive pinion Nm > 180 125
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-1003-02A Oil drain screw for rear axle differential Nm 50
BA35.31-P-1005-02A Breather, rear axle differential Nm 30
TORQUE SPECIFICATION PROPELLER SHAFT

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 -
TORQUE SPECIFICATION SAFETY BELTS

Number Designation Model 140
BA91.40-P-1001-01B Nut for bracket holding safety belt anchorage to floorpan Nm 270
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 center assembly 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 center assembly 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 center assembly Liters 1,3
Specifications for Operating Fluids Sheet -
Sheet BB00.40-P-0235-07A
Fig 2: Identifying Torque Meter (001 589 49 21 00)
G05437473Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Connecting Piece (100 589 02 59 00)
G05437474Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Pin Wrench (129 589 01 07 00)
G05437475Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Wrench Socket (126 589 02 09 00)
G05437476Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 6: Identifying Puller (129 589 01 33 00)
G05437477Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 7: Identifying Drift (208 589 00 15 00)
G05437478Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 8: Identifying Drift (140 589 02 15 00)
G05437479Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 9: Identifying Open End Wrench (126 589 00 01 00)
G05437480Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 10: Identifying Drift (140 589 08 15 00)
G05437481Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 11: Identifying Drift (140 589 13 15 00)
G05437482Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
AUXILIARY 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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