Disassemble/assemble rear axle center assembly, adjusting gear set - AR35.31-P-0550B

Rear axle center assembly dia. 168 in model 124.104 up to 30.4.94, 124.105 /106, 124.107 up to 30.4.94, 170.435, 202.180 

Rear axle center assembly dia. 168 in model 124.020 /021 /080 /081 /120 /125 /126 /180 /185, 124.186 up to 28.2.94, 201.018 /023 /024 /122 /126, 202.018 /078 /120 /121 /122 /125 /182, 210.003 /004 except CODE (450) taxi version 

Rear axle center assembly dia. 168 in MODEL 124.020 /021 /080 /081 /120 /125 /126 /180 /185 /186, 201.018 /023 /024 /122 /126 up to 31.10.88 with CODE (450) taxi version 

Rear axle center assembly dia. 168 in MODEL 202.018 /120 /121 /125 except CODE (211a) Rear axle with automatic locking differential (ASD) 

17.5.04	Oil filler screw and oil drain screw at rear axle center assembly modified	as of 19.01.04 Always replace oil filler and drain screws after unscrewing Clean new oil filler and drain screws as well as the threaded holes with a special cleaning agent and apply special sealant	BT35.31-P-0015-01A
	The oil drain screw must always be replaced with a new screw after removal from the rear axle center assembly. The new oil drain screw and the tapped hole must be cleaned using a special cleaning spray and a special sealing compound must be applied to the oil drain screw.		AR35.31-P-0520-06A
	The oil filler screw must always be replaced with a new screw after removal from the rear axle center assembly. The new oil filler screw and the tapped hole must be cleaned using a special cleaning spray and a special sealing compound must be applied to the oil filler screw.	Carry out oil level check only at room temperature.
		Model 170, 202, 210	AR35.31-P-0520-03A
		Model 124, 201	AR35.31-P-0520-03AA

	Remove
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
1	Raise vehicle with lifting platform
2	Drain oil from rear axle center assembly (50)		AR35.31-P-0520-06A
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Omnifit 1 sealing compound 00H (50g)	*BR00.45-Z-1061-01A
		Oil drain plug	*BA35.31-P-1003-02A
	Oil filler screw and oil drain screw at rear axle center assembly modified	as of 19.01.04	BT35.31-P-0015-01A
3	Remove rear axle center assembly (50)	Model 124, 201	ra35001240520x
		Model 170, 202	AR35.31-P-0520D
		Model 210	AR35.31-P-0520B
	Threaded bore for rpm sensor routed at rear axle housing	Model 124, 201	BT35.31-P-0004-01A
	Features, installation summary for rear axle center assembly		GF35.31-P-1000-01B
	Disassemble
4	Clamp rear axle center assembly (50) in assembly stand		AR35.31-P-0540-06B
5	Detach end cover (54)
	End cover (54) with unmachined sealing surface	Model 170, 202, 210 as of 08.05.00	BT35.31-P-0014-01A
6	Detach circlips (30) from both connecting flanges (33 or 33d)		AR35.31-P-0540-01A
7	Pull out connecting flanges (33 or 33d)
8	Pry off left and right radial seal ring (32)		AR35.31-P-0540-05E
9	Remove shim (31a) on the end face of the differential case
10	Using the spreader, remove the left-hand circlip (29) from the rear axle housing	Mark circlip (29).	AR35.31-P-0550-01B
11	Take the right-hand circlip (29) out of the rear axle housing	Mark circlip (29).	*WH58.30-Z-1009-02A
12	Remove both tapered roller bearing outer races (11a) out of rear axle housing	Mark tapered roller bearing outer races (11a).	AR35.31-P-0550-02B
13	Remove differential (13) from rear axle housing		AR35.31-P-0550-03B
14	Pull both tapered roller bearing inner races (11b) off differential (13)	Mark tapered roller bearing inner races (11b).	AR35.31-P-0550-04B
15	Slacken and remove retaining bolts (13a) from crown wheel (47a)	Mark position of ring gear (47a) relative to differential (13).
16	Carefully press off crown wheel (47a) from differential (13)
17	Slacken and unscrew twelve-point collar nut (40) from joint flange (41)		AR35.31-P-0550-35B
18	Detach joint flange (41)	If necessary, mark joint flange (41) relative to drive pinion.	AR35.31-P-0550-06B
19	Press drive pinion (47) out of rear axle housing		AR35.31-P-0550-07B
20	Press radial sealing ring (42) out of the rear axle housing using a suitable screwdriver		AR35.31-P-0550-08B
21	Remove tapered roller bearing inner race (43d)
22	Remove tapered roller bearing outer races (46b, 43e) and shim (45) from rear axle housing		AR35.31-P-0550-09B
23	Remove spacer sleeve (44) with thrust plates (48) from drive pinion (47)
24.1	Pull ABS gear (49) off drive pinion (47)	Vehicles with antilock brake system (ABS) code 470a, except vehicles with ETS, ASR, ESP	AR35.31-P-0550-30B
25	Pull tapered roller bearing inner race (46a) from drive pinion (47)		AR35.31-P-0550-10B
	Check
26	Check all parts for reusability and replace if necessary	If the contact surfaces of the connecting and joint flanges show signs of severe galling due to the radial sealing ring, the flanges must be replaced.
27.1	Check drive pinion (47) and ring gear (47a) for match-up number	Only lapped gear assembly up to approx. 06/95 is provided with match-up number. Each lapped gear set is checked for the best possible smooth running and marked with a consecutive match-up number that is marked on both parts	AR35.31-P-0550-11A
	Ground gear sets	Phased in as of 06/95	BT35.31-P-0011-01B
	Assembly, adjusting gear set
28	Press tapered roller bearing inner race (46a) onto drive pinion (47)		AR35.31-P-0550-12B
	Press-on sleeve for tapered roller bearing inner race		WF58.50-P-3531-03B
29.1	Press ABS gear (49) onto drive pinion (47)	Vehicles with antilock brake system (ABS) code 470a, except vehicles with ETS, ASR, ESP	AR35.31-P-0550-31B
	Press-on sleeve for ABS gear wheel		WF58.50-P-3531-04B
		Number of teeth on ABS gear: ↓ Features, installation summary for rear axle center assembly	GF35.31-P-1000-01B
30	Calculate thickness for shim (45) and install in rear axle housing	Use data sheet: ↓ Data sheet, Adjusting rear axle gear set: Order No. B20.800.98.113.00C	AR35.31-P-0550-13B
31	Pull tapered roller bearing outer races (46e, 43b) into rear axle housing		AR35.31-P-0550-14B
32	Install spacer sleeve (44) on drive pinion (47) with double-sided thrust plates (48)	Always replace spacer sleeve (44) and thrust plates (48).	AR35.31-P-0550-26B
33	Insert drive pinion (47) into rear axle housing.	Support drive pinion (47) with removal, installation device.	AR35.31-P-0550-15B
34	Mount tapered roller bearing inner race (43d) on drive pinion (47) and press in together with radial sealing ring (42)	Replace radial sealing ring (42) and coat the lip with universal hypoid gear oil.	AR35.31-P-0550-16B
	Universal hypoid-gear lubricants		BB00.40-P-0235-07A
	Modified radial seal ring	Model 124, 201	BT35.31-P-0008-01A
35	Slide joint flange (41) onto drive pinion (47)	Observe possible applied marking. Coat contact surface for radial seal ring with universal hypoid gear oil.
	Universal hypoid-gear lubricants		BB00.40-P-0235-07A
	Protection ring on drive pinion joint flange lengthened	Model 124, 201	BT35.31-P-0003-01A
	Imbalance at drive pinion joint flange reduced	Model 124, 201	BT35.31-P-0007-01A
	Hole diameter of drive pinion joint flange increased	Model 124, 201	BT35.31-P-0010-01A
36	Screw on twelve-point collar nut (40)	Replace twelve-point collar nut (40).
		Socket wrench bit	Figure
37	Adjust friction torque of drive pinion bearing		AR35.31-P-0550-17B
38	Check adjustment dimension for drive pinion (47)		AR35.31-P-0550-18B
39	Secure twelve-point collar nut (40) on joint flange (41)		AR35.31-P-0530-01B
	Caulker for securing twelve-point collar nut (40) on joint flange (41)		WF58.50-P-3531-01A
40	Disassemble and assemble differential (13)		AR35.31-P-0560B
41	Mount ring gear (47a) on differential (13)	Observe the marking applied to the ring gear (47a) and differential (13).	AR35.31-P-0550-19B
	Tightening torque of crown wheel bolts reduced	Model 124, 201 as of 01.02.87	BT35.31-P-0005-01A
42	Press tapered roller bearing inner races (11b) onto the differential (13)		AR35.31-P-0550-20B
43	Insert differential (13) into rear axle housing		AR35.31-P-0550-03B
44	Install right tapered roller bearing outer race (11a) in rear axle housing		AR35.31-P-0550-21B
45	Install right circlip (29)	Install the circlip (29) removed and marked previously in order to achieve a basic pre-tension of the rear axle housing.	AR35.31-P-0550-22B
46	Take left-hand drift out of differential (13)
47	Insert left tapered roller bearing outer race (11a) into rear axle housing	The tapered roller bearing outer race (11a) must abut the tapered roller bearing inner race (11b).
48	Pre-tension (spread) rear axle housing with spreader		AR35.31-P-0550-23B
49	Install left locking ring (29)	Install the circlip (29) removed and marked previously in order to achieve a basic pre-tension of the rear axle housing.	AR35.31-P-0550-27B
50	Release tension of rear axle housing
51	Measure spread (expansion) of rear axle housing		AR35.31-P-0550-24B
52	Measure the gear backlash between the drive pinion (47) and ring gear (47a) and correct if necessary	The adjustment of the tapered roller bearing and the gear set are okay, when the spreading dimension (widening) of the rear axle housings and the gear backlash are within the nominal values. This can prevent damage to the teeth of the drive pinion (47) and ring gear (47a)	AR35.31-P-0550-25B
53	Dismantle spreader and stop from rear axle housing
54	Ensure correct seat of circlip (29)		AR35.31-P-0550-32B
55	Insert shim (31a) in differential (13)	The shim (31a) must abut the end face of the differential firmly.	AR35.31-P-0550-33B
56	Press radial sealing rings (32) into the rear axle housing	Replace radial sealing ring (32) and coat the lip with universal hypoid gear oil.	AR35.31-P-0540-05E
	Universal hypoid-gear lubricants		BB00.40-P-0235-07A
	Radial seal rings modified	Model 124, 201	BT35.31-P-0008-01A
57	Install connecting flanges (33 or 33d) in differential (13)
	Connecting flange with centering	Model 124, 201	BT35.31-P-0009-01A
58	Mount circlips (30) on both connection flanges (33 or 33d)	Replace circlip (30).	AR35.31-P-0540-01A
59	Check axial play of connecting flange (33 or 33d) and adjust if necessary		AR35.31-P-0540-02D
60	Attach end cover (54)	If a replacement part end cover is mounted, it is essential to observe whether the sealing surface is machined or unmachined. Use suitable sealant.
		End cover (54) with machined sealing surface in models 124, 201 and in models 170, 202, 210 up to 07.05.00	AR35.31-P-0550-28B
		End cover (54) with unmachined sealing surface in models 170, 202, 210 as of 08.05.00	AR35.31-P-0550-28BA
	Rear axle center assembly end cover with unmachined sealing surface	Model 170, 202, 210 as of 08.05.00	BT35.31-P-0014-01A
61	Replace rear axle breather (55) on end cover (54)		*BA35.31-P-1005-02A
62	Detach rear axle center assembly (50) from assembly stand
	Install
63	Install rear axle center assembly (50)	Model 124, 201	ra35001240520x
		Model 170, 202	AR35.31-P-0520D
		Model 210	AR35.31-P-0520B
64	Pour oil into the rear axle center assembly (50)	Model 170, 202, 210	AR35.31-P-0520-03A
		170	*BF35.31-P-1001-01F
		202	*BF35.31-P-1001-01D
		210	*BF35.31-P-1001-01E
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Omnifit 1 sealing compound 000H (50g)	*BR00.45-Z-1061-01A
		Oil filler screw for rear axle center assembly	*BA35.31-P-1002-02A
		Model 124, 201	AR35.31-P-0520-03AA
		124	*BF35.31-P-1001-01B
		201	*BF35.31-P-1001-01G
		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 center assembly	*BA35.31-P-1002-02A
	Oil filler screw and oil drain screw at rear axle center assembly modified	as of 19.01.04	BT35.31-P-0015-01A

Number	Designation		Model 124.020/021/080/081/120/125/126/180/185, except (code 450) taxi version	Model 124.020/021/080/081/120/125/126/180/185/186, with (code 450) taxi version up to 31.10.88	Models 124.104/107 up to 30.04.94 Model 124.105/106 Model 124.186 up to 28.02.94, except (code 450) taxi version
BE35.31-P-1001-02B	Friction torque of drive pinion bearing (new tapered roller bearings)	Ncm	120-140	120-140	120-140

Number	Designation		Model 170.435	Model 201.018/023/024/122/126, except (code 450) taxi version	Model 201.018/023/024/122/126, with (code 450) Taxi version up to 31.10.88
BE35.31-P-1001-02B	Friction torque of drive pinion bearing (new tapered roller bearings)	Ncm	120-140	120-140	120-140

Number	Designation		Model 202.018/078/120/121/122/125/182, except (code 450) taxi version, Model 202.018/120/121/125 without ASD (code 211), Model 202.180	Model Series 210.003/004 except (Code 450) Taxi version
BE35.31-P-1001-02B	Friction torque of drive pinion bearing (new tapered roller bearings)	Ncm	120-140	120-140

Number	Designation		Model 124	Model 170	Model 201
BE35.31-P-1001-03A	Permissible deviation from specified adjustment dimension on end face of drive pinion	mm	-0.02/+0.01	-0.02/+0.01	-0.02/+0.01
BE35.31-P-1002-03A	Gear backlash between crown wheel and pinion	mm	0,08-0,14	0,08-0,14	0,08-0,14
BE35.31-P-1003-03A	Ring gear heating temperature during installation	°C	75-85	75-85	75-85

Number	Designation		Model 202	Model 210
BE35.31-P-1001-03A	Permissible deviation from specified adjustment dimension on end face of drive pinion	mm	-0.02/+0.01	-0.02/+0.01
BE35.31-P-1002-03A	Gear backlash between crown wheel and pinion	mm	0,08-0,14	0,08-0,14
BE35.31-P-1003-03A	Ring gear heating temperature during installation	°C	75-85	75-85

Number	Designation		Model 124.020/021/080/081/120/125 /126/ 180/185 except (code 450) taxi version	Model 124.020/021/080/081/120/125/126/180/185/186, with (code 450) taxi version up to 31.10.88	Model 124.104/107 up to 30.04.94, Model 124.105/106 Model 124.186 up to 28.02.94, except (code 450) taxi version
BE35.31-P-1001-04B	Rear axle housing expansion (spread dimension) when removing locking ring	mm	0,2	0,2	0,2
BE35.31-P-1002-04B	Rear axle housing expansion (expanded dimension) for circlip installation	mm	0.25	0.25	0.25
BE35.31-P-1003-04B	Setting for rear axle housing expansion (spread dimension)	mm	0,13-0,18	0,13-0,18	0,13-0,18

Number	Designation		Model 170.435	Model 201.018/023/024/122/126, except (code 450) taxi version	Model 201.018/023/024/122/126, with (code 450) Taxi version up to 31.10.88
BE35.31-P-1001-04B	Rear axle housing expansion (spread dimension) when removing locking ring	mm	0,2	0,2	0,2
BE35.31-P-1002-04B	Rear axle housing expansion (expanded dimension) for circlip installation	mm	0.25	0.25	0.25
BE35.31-P-1003-04B	Setting for rear axle housing expansion (spread dimension)	mm	0,13-0,18	0,13-0,18	0,13-0,18

Number	Designation		Model 202.018/078/120/121/122/125/182, except (code 450) taxi version, Model 202.018/120/121/125 without ASD (code 211), Model 202.180	Model Series 210.003/004 except (Code 450) Taxi version
BE35.31-P-1001-04B	Rear axle housing expansion (spread dimension) when removing locking ring	mm	0,2	0,2
BE35.31-P-1002-04B	Rear axle housing expansion (expanded dimension) for circlip installation	mm	0.25	0.25
BE35.31-P-1003-04B	Setting for rear axle housing expansion (spread dimension)	mm	0,13-0,18	0,13-0,18

Number	Designation		MODEL 124	Model 170	Model 201	Model 202	Model 210
BE35.31-P-1001-05A	Axial play between connecting flange and differential housing	mm	0.03...0.3	0.03...0.3	0.03...0.3	0.03...0.3	0.03...0.3

Number	Designation				Model 124	Model 170
BA35.31-P-1001-02A	Bolt, end cover to rear axle center assembly	Bolt+washer		Nm	50	-
		Flange bolt (TORX, internal serrations)	1st stage	Nm	30	30
			2nd stage	∠ °	45	45
BA35.31-P-1002-02A	Oil filler plug, rear axle center assembly			Nm	50	50
BA35.31-P-1003-02A	Oil drain screw for rear axle center assembly			Nm	50	50
BA35.31-P-1005-02A	Rear axle center assembly breather			Nm	25	25

Number	Designation				Model 201	Model 202
BA35.31-P-1001-02A	Bolt, end cover to rear axle center assembly	Bolt+washer		Nm	50	50
		Flange bolt (TORX, internal serrations)	1st stage	Nm	30	30
			2nd stage	∠ °	45	45
BA35.31-P-1002-02A	Oil filler plug, rear axle center assembly			Nm	50	50
BA35.31-P-1003-02A	Oil drain screw for rear axle center assembly			Nm	50	50
BA35.31-P-1005-02A	Rear axle center assembly breather			Nm	25	25

Number	Designation				Model 210
BA35.31-P-1001-02A	Bolt, end cover to rear axle center assembly	Bolt+washer		Nm	50
		Flange bolt (TORX, internal serrations)	1st stage	Nm	30
			2nd stage	∠ °	45
BA35.31-P-1002-02A	Oil filler plug, rear axle center assembly			Nm	50
BA35.31-P-1003-02A	Oil drain screw for rear axle center assembly			Nm	50
BA35.31-P-1005-02A	Rear axle center assembly breather			Nm	30

Number	Designation		Model 124.020/021/080/081/120/125/126/180/185, except (code 450) taxi version	Model 124.020/021/080/081/120/125/126/180/185/186, with (code 450) taxi version up to 31.10.88	Model 124.104/107 up to 30.04.94, model 124.105/106, model 124.186 up to 28.02.94, except (code 450) taxi version	Model 170.435
BA35.31-P-1001-03B	Ring gear securing bolt at differential gear housing	Nm	85	85	85	85

Number	Designation		Model 201.018/023/024/122/126 except (code 450) taxi version	Model 201.018/023/024/122/126, with (code 450) taxi version up to 31.10.88	Model 202.018/078/120/121/122/125/182, except (code 450) taxi version, Model 202.018/120/121/125 without ASD (code 211), Model 202.180
BA35.31-P-1001-03B	Ring gear securing bolt at differential gear housing	Nm	85	85	85

Number	Designation		Model 210.003/004 except (code 450) taxi version
BA35.31-P-1001-03B	Ring gear securing bolt at differential gear housing	Nm	85

Number	Designation			Model 124.104 /107 up to 30.04.94 without (code 211) ASD Model 124.105/106 without (code 211) ASD Model 124.186 without (code 211) ASD up to 28.02.94, except (code 450) taxi version	Model 124.020/021/080/081/120/125/126/180/185, without (code 211) ASD, except (code 450) taxi version
BF35.31-P-1001-01B	Filling capacity	Rear axle center assembly	Liters	0.7	0.7
		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

Number	Designation			Model 124.020/021/080/081/120/125/126/180/185/186, without (code 211) ASD, with (code 450) taxi version up to 31.10.88
BF35.31-P-1001-01B	Filling capacity	Rear axle center assembly	Liters	0.7
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-00A
			Sheet	BB00.40-P-0235-07A

Number	Designation			Model 202.018/078/120/121/122/125/182 except (code 450) taxi version, Model 202.018/120/121/125, without (code 211) ASD, Model 202.180
BF35.31-P-1001-01D	Filling capacity	Rear axle center assembly	Liters	0.7
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-00A
			Sheet	BB00.40-P-0235-07A

Number	Designation			Model 210.003/004 except Code 450
BF35.31-P-1001-01E	Filling capacity	Rear axle center assembly	Liters	0.7
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A

Number	Designation			Model 170.435
BF35.31-P-1001-01F	Filling capacity	Rear axle center assembly	Liters	0.7
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A

Number	Designation			Model 201.018/023/024/122/126, without (code 211) ASD, except (code 450) taxi version	Model 201.018/023/024/122/126, without (code) ASD, with (code 450) taxi version up to 31.10.88
BF35.31-P-1001-01G	Filling capacity	Rear axle center assembly	Liters	0.7	0.7
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-00A	BB00.40-P-0235-00A
			Sheet	-	-

Number	Designation
WH58.30-Z-1009-02A	Pliers for circlip, inner

Number	Designation	Order number
BR00.45-Z-1061-01A	Sealant, Omnifit 100H (50 g)	-
BR00.45-Z-1013-01A	Sealant	A 003 989 98 20
BR00.45-Z-1010-01A	Sealant	A 001 989 25 20
BR00.45-Z-1046-04A	Cleaning spray, Loctite 7063 (150ml)	A 001 986 71 71 10