Replace radial sealing ring on connecting flange of rear axle shaft - AR35.31-P-0540A: Notes

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 differential dia. 198 in MODEL 140.02 /03 as of 1.6.94

Rear axle differential dia. 210

in model 140.02 /03 up to 31.5.94,

140.04 /06 /1

Rear axle differential dia. 210 in MODEL 140.05 /07

Rear axle center assembly reinforced

Model 140.02/03 up to 31.05.94,

Model 140.04/05/06/07/1

Fig 1: Identifying Rear Axle Center Assembly

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Models 140.02/03 as of 01.06.94

Fig 2: Identifying Rear Axle Center Differential Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	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
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
		Oil drain screw	*BA35.31-P-1003-02A
	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04	BT35.31-P-0015-01A
3	Detach rear axle shafts (37) from the connecting flanges	Move the rear axle shaft into approximately the horizontal position and push together. Remove rear axle shaft downwards and tie up at rear springs. Installation: Replace self-locking multipoint or hexagon socket bolts and washers. Lightly oil bolts at thread and bolt head contact surface.
			*BA35.30-P-1002-01A
4	Support rear axle differential (50)	Assembly attachment	Figure
5	Detach extension bracket (54a)	In order to remove the extension bracket, push the right-hand hexagon bolt in the rear axle crossmember back towards the spare wheel well.
		Installation: Replace self-locking nut (62b).	*BA35.10-P-1001-02A
		Bolt (54b): ↓	*BA35.10-P-1002-02A
		Stiffer spring control arm rubber mounts	BT35.10-P-0003-01A
6	Remove end cover (54)	Installation: Clean installation and coat with sealing compound.	*BR00.45-Z-1010-01A
		Replace bolts (56b).
		Bolts (56b), bolts (56)	*BA35.31-P-1001-02A
7	Detach circlip (30)	Replace circlip.	AR35.31-P-0540-01A
		Removal and installation tool	Figure
8	Pull out connecting flange (33, 33a, 33b)	Check contact surface for radial sealing ring on connecting flange; if it is severely galled: ↓ Replace connecting flange.
		Installation: Check, adjust axial play of connecting flange: ↓
		Axial play adjustment is not necessary for vehicles with rear axle with automatic locking differential (ASD), code 211a.
		Model 140.02/03 up to 31.5.94 and 140.04/06/1 or vehicles with acceleration slip regulation (ASR), code 471a	AR35.31-P-0540-02A
		Axial play between connecting flange and differential housing	*BE35.31-P-1001-05A
		Model 140.02/03 as of 1.6.94	AR35.31-P-0540-02C
		Axial play between connecting flange and differential housing	*BE35.31-P-1001-05A
		Model 140.05/07	AR35.31-P-0540-02B
		Axial play between connecting flange and differential housing	*BE35.31-P-1001-05A
	Radial seal on side of rear axle housing and connecting flange modified	As of 01.10.01 with model 140 with rear axle differential dia. 198 mm	BT35.31-P-0013-01B
9	Press protective ring off connecting flange	As of 01.10.01 with model 140 with rear axle differential dia. 198 mm	AR35.30-P-0620-05R
		If a new radial sealing ring is installed for the first time, a new protection ring must also be installed. This is the only way to ensure a proper seal.
		Drift	Fig 13
10	Detach grooved ball bearing	Vehicles with rear axle with automatic locking differential (ASD),,ode 211a, vehicles with acceleration slip regulation (ASR), code 471a	AR35.31-P-0540-04A
		Puller	Figure
		Clamping pliers	Figure
11	Press off radial sealing ring (32, 32a, 70j)	Installation: Replace radial sealing ring and smear sealing lip with Universal hypoid gear oil: ↓
		Universal hypoid-gear lubricants	BB00.40-P-0235-07A
		Model 140.02/03 up to 31.5.94 and 140.04/06/1 or vehicles with acceleration slip regulation (ASR), code 471a (Rear axle differential ø 210 mm)	Fig 4
		Model 140.1 with rear axle with automatic locking differential (ASD), code 211a	AR35.31-P-0540-05A
		Extractor tool	Figure
		Drift	Figure
		Model 140.02/03 up to 31.5.94 and 140.04/06/1 (basic version with radial sealing ring, outside ø 65 mm)	AR35.31-P-0540-05B
		Drift	Figure
	Rear axle center assembly crown wheel diameter modified	Models 140.02/03 as of 06/94	BT35.31-P-9406-01A
		Models 140.02/03 as of 1.6.94, with and without	AR35.31-P-0540-05C
		ASR / ETS (rear axle differential ø 198 mm)
		Drift	Figure
	Radial seal on side of rear axle housing and connecting flange modified	As of 01.10.01 with model 140 with rear axle differential dia. 198 mm	BT35.31-P-0013-01B
		Models 140.05/07	AR35.31-P-0540-05D
		Drift	Figure
12	Replace breather (55) of rear axle differential		*BA35.31-P-1005-02A
13	Install in the reverse order
14	Check oil level in rear axle differential and correct if necessary	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
		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
		Oil filler screw for rear axle differential	*BA35.31-P-1002-02A
	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04	BT35.31-P-0015-01A

TEST VALUES FOR CONNECTING FLANGE/DIFFERENTIAL HOUSING

Number	Designation		Model 140
BE35.31-P-1001-05A	Axial play between connecting flange and differential housing	mm	0,03-0,3

EXTENSION BRACKET FOR REAR AXLE CENTER ASSEMBLY

Number	Designation			Model 140
BA35.10-P-1001-02A	Self-locking nut securing rear extension bracket to rear axle carrier		Nm	100
BA35.10-P-1001-02A			∠°	-
BA35.10-P-1002-02A	Bolt, extension bracket to rear axle center assembly	Yellow	Nm	80
BA35.10-P-1002-02A	Bolt, extension bracket to rear axle center assembly	Silver or blue	Nm	70

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
BA35.30-P-1002-01A		M12	Nm	100

REAR AXLE CENTER ASSEMBLY HOUSING

Number	Designation				Model 140
BA35.31-P-1001-02A	Bolt, end cover to rear axle differential	Bolt+washer		Nm	50
		Flange bolt (TORX, internal serrations)	Stage 1	Nm	30
		Flange bolt (TORX, internal serrations)	Stage 2	∠°	45
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 center assembly			Nm	30

REAR AXLE DIFFERENTIAL

Number	Designation			Models series 140.02/03 without (code 211) 05/94	Models 140.02/03 as of 06/94	Models series 140.02/03 with (code 211) ASD up to 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	-
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	BB00.40-P-0235-07A	BB00.40-P-0235-07A

REAR AXLE DIFFERENTIAL

Number	Designation			Models series 140.04/06	Models 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
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	-	BB00.40-P-0235-07A

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	-
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A

Fig 3: Identifying Drift (140 589 03 15 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Drift (126 589 04 15 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Drift (140 589 06 15 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Drift (140 589 10 15 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Identifying Drift (124 589 01 15 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying Extraction Tool (129 589 02 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 9: Identifying Puller (001 589 50 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 10: Identifying Clamping Pliers (140 589 00 34 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 11: Identifying Assembly Attachment (140 589 01 62 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 12: Identifying Removal and installation tool (116 589 01 62 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 13: Identifying Drift (140 589 16 15 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1010-01A	Sealant	A 001 989 25 20
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