Pressing out and drawing in rear axle shaft at rear axle shaft flange - AR35.30-P-0115-03B

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.

Rear axle shafts with forged centers (without core hole)

Models 129, 140, 202, 210 as of 31.1.96

BT35.30-P-0005-01A

Fig 1: Identifying Extraction And Installation Tool (210 589 03 43 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Bracket (210 589 01 40 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Rear axle shaft with forged center (without core hole drill hole)

Pressing out

Screw nut onto threaded bolt.
Screw in and tighten the threaded bolt in the threaded spindle of the extraction and insertion tool.
Push out rear axle shaft using extractor and insertion tool and remove.
Inserting

On rear axle shafts which are glued in before installation clean the splined shaft profile and rear axle shaft flange mechanically. If the shaft is stiff, cut a M8 thread into the shaft so that this can be pulled in with the extractor and insertion tool.

Fig 3: Identifying Rear Axle Shaft With Extraction And Insertion Tool
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Screw bracket (039) onto shaft journal of rear axle shaft (37) and clamp in vise.
Rear axle shaft with M24 1.5 thread shown

Fig 4: Identifying Rear Axle Shaft With Forged Center (Without Core Hole Drill Hole)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Insert 4 mm dia. drilling bush (detachable) (039a) and lock with mounting screw (039c).
Rear axle shaft with M24 1.5 thread shown

Fig 5: Identifying Rear Axle Shaft With M24 1.5 Thread
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Using a drill (4 mm dia.), drill core hole drill hole approx. 20 mm deep, cooling and lubricating the drill.
Remove 4 mm dia. drilling bush (detachable) (039a) with mounting screw (039c).
Using drill (6.8 mm dia.), drill out core hole drill hole approx. 20 mm deep, cooling and lubricating the drill.

Fig 6: Identifying Drilling Measurement And Mounting Screw
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Pre-cut thread M8 using stage 1 and stage 2 tap.
Unscrew bracket (039) from rear axle shaft and clamp rear axle shaft in vise
Finish-cut thread M8 using stage 3 tap.
Using extraction and insertion tool, draw rear axle shaft into the rear axle shaft flange.

Fig 7: Identifying Bracket And Clamp Rear Axle Shaft

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.