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Home >> Mercedes Benz >> 1997 >> C230 >> Repair and Diagnosis >> Suspension >> Rear Suspension >> Rear Axle -- 202 Chassis >> Testing & Repair >> Remove/install rear axle differential - AR35.31-P-0520D

Remove/install rear axle differential - AR35.31-P-0520D

Rear axle differential dia. 168 in MODELS 170, 202 

Rear axle differential dia. 185 in MODEL 170, 202, 208 

Rear axle differential dia. 198 in MODEL 170, 202, 208 

Rear axle differential dia. 210 in MODEL 208 

Rear axle center assembly 210E 

Fig 1: Identifying Rear Axle Differential Remove/Install Components - Rear Axle Differential Dia. 168, 185, 198
G04713464
MODIFICATION NOTES

20.3.04 Oil filler/drain screw on rear axle differential modified Phased in as of 19.01.04
IMPORTANT The oil filler screws and oil drain screws should always be replaced after being unscrewed.
The new oil filler screws and drain screws as well as the tapped holes must be cleaned with a special cleaning spray and provided with a special sealing compound		 BT35.31-P-0015-01A
  The oil filler screw should always be replaced after being unscrewed from the rear axle center assembly. The new oil filler screw as well as the tapped hole must be cleaned with a special cleaning spray and the oil filler screw provided with a special sealing compound IMPORTANT Only carry out oil level check at interior temperature. AR35.31-P-0520-03A
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
REFER TO BASIC KNOWLEDGE Features, installation survey for rear axle differentials Rear axle center assembly with crown wheel dia. 168 mm GF35.31-P-1000-01B 
REFER TO BASIC KNOWLEDGE Features, installation survey for rear axle differentials Rear axle center assembly with crown wheel dia. 185 mm GF35.31-P-1000-01C 
REFER TO BASIC KNOWLEDGE Features, installation survey for rear axle differentials Rear axle center assembly with crown wheel dia. 198 mm GF35.31-P-1000-01A 
REFER TO BASIC KNOWLEDGE Features, installation survey for rear axle differentials Rear axle center assembly with 210 mm crown wheel dia. in rear axle center assembly 210E GF35.31-P-1000-01I 
1 Raise vehicle with lifting platform    
2.1 Detach hydraulic line (HS) Model Series 202 with ASD up to 05/94
IMPORTANT Seal thread opening on ring cylinder and hydraulic line (HS).		  
3.1 Remove rear axle rpm sensor (L6) If installed.
IMPORTANTInstallation:  Clean magnetic blade and replace O-ring.		 ra42001240714x
4.1 Remove rear left and right rpm sensor (L6/3, L6/4) Model 202 with ASR up to 05/94 ra42002020820x
5 Remove exhaust system (105) from flange connection See ↓
Remove exhaust system (105) complete		  
    Model 170 with engines 111.943/946/973 AR49.10-P-7000G
    Model Series 170 with Engine 111.958/983 AR49.10-P-7000GS
    Model 170 with Engine 112 AR49.10-P-7000SV
    Model Series 202 with Series 104, 111 engine AR49.10-P-7000D
    Model 202 with engine 601 ra49006010100x
    Model 202 with engine 604, 605 AR49.10-P-7000I
    Model 202 with engine 611 AR49.10-P-7000HB
    Model 202 with engine 112.910/920, 113.944
Model 208 with engine 112.940, 113.943/984		 AR49.10-P-7000AU
    Model 208 with engine 111.945/975 AR49.10-P-7000DA
6 Remove exhaust heat shield (105c)    
7.1 Loosen propeller shaft clamping nut (106c) Model 202 up to approx. 10/95  
    SPECIAL TOOL Open-end wrench 46 mm Figure
    SPECIAL TOOL Open-end wrench 41 mm Figure
    TORQUE SPECIFICATION *BA41.10-P-1003-01A 
REFER TO COMPONENT MODIFICATIONS Clamp connection of propeller shaft Model 202: Changed over to sliding piece connection. BT41.10-P-9110-01DA
8 Detach propeller shaft intermediate bearing (106a) IMPORTANTInstallation:  Only tighten the bolts of the propeller shaft intermediate bearing (106a) after fixing the flexible coupling to the rear axle center assembly (50).  
    TORQUE SPECIFICATION *BA41.40-P-1001-01A 
9 Detach the rear propeller shaft (106) from the rear axle center assembly (50) IMPORTANT The flexible coupling remains on the rear propeller shaft (106).
With firmly attached fitted sleeves: ↓		  
    Loosen fitting sleeves on flexible couplings. AR41.10-P-0050-09DA
REFER TO SHOP-MADE TOOLS Drift for loosening fitting sleeves in flex disks.   WF58.50-P-4110-01A
    IMPORTANT Place rear propeller shaft (106) on the reinforcement bracket.  
    TORQUE SPECIFICATION *BA41.10-P-1002-01A 
10.1 Detach cover (140) of fuel pump assembly and unhook fuel pump assembly from the rubber rings Vehicles with gasoline engines  
11 Detach rear axle shafts (37) from the connecting flanges IMPORTANT Move the rear axle shaft (37) into approximately the horizontal position and push together. Tie the rear axle shafts (37) securely to the rear axle carrier.
IMPORTANTInstallation:  Replace self-locking multipoint, hexagon socket or torx bolts and washers.
Lightly oil bolts at thread and bolt head contact surface.		  
    TORQUE SPECIFICATION *BA35.30-P-1002-01A 
12 Support rear axle differential (50) SPECIAL TOOL Assembly attachment Figure
13 Unscrew bolts (50a) and remove stop plate (50b)   AR35.31-P-0520-02A 
    TORQUE SPECIFICATION *BA35.10-P-1004-01A 
14 Remove front center assembly mounting    
    IMPORTANTInstallation:  Attach front center assembly mounting AR35.10-P-0050-01A 
    TORQUE SPECIFICATION *BA35.10-P-1003-01A 
REFER TO COMPONENT MODIFICATIONS Front suspension on rear axle center assembly modified Model 202.018/022/028/120/121/125 as of 07/93 BT35.31-P-0001-01B 
15 Lower and remove rear axle center assembly (50)    
16 Replace rear axle center assembly breather TORQUE SPECIFICATION *BA35.31-P-1005-02A 
17 Install in the reverse order    
18.1 Bleed ASD hydraulic system Model Series 202 with ASD up to 05/94 AR35.41-P-0519C 
19 Check oil level in rear axle differential and correct if necessary IMPORTANT Mixing old Universal hypoid gear oil and the FE-hypoid gear oil should be avoided for better fuel economy. AR35.31-P-0520-03A
    FLUID SPECIFICATION Model 170 *BF35.31-P-1001-01F 
    FLUID SPECIFICATION Model 202 *BF35.31-P-1001-01D 
    FLUID SPECIFICATION Model 208 *BF35.31-P-1001-01H 
    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 CARRIER

Number Designation Model 170 Model 202 Model 208
BA35.10-P-1003-01A Self-locking nut, rear axle differential at front to rear axle carrier Nm 50 50 50
BA35.10-P-1004-01A Self-locking bolt, rear axle differential at rear to rear axle carrier Nm 110 110 110
TORQUE SPECIFICATION REAR AXLE SHAFT

Number Designation Model 170 Model 202 Model 208
BA35.30-P-1002-01A Self-locking bolt, rear axle shaft to connecting flange (thread and bolt head contact surface oiled) M10 Nm 70 70 70
M12 Nm - - -
TORQUE SPECIFICATION REAR AXLE CENTER ASSEMBLY HOUSING

Number Designation Model 170 Model 202
BA35.31-P-1002-02A Oil filler screw, rear axle differential Nm 50 50
BA35.31-P-1005-02A Breather, rear axle center assembly Nm 25 25
TORQUE SPECIFICATION REAR AXLE CENTER ASSEMBLY HOUSING

Number Designation Model 208
BA35.31-P-1002-02A Oil filler screw, rear axle differential Nm 50
BA35.31-P-1005-02A Breather, rear axle center assembly Nm 25
TORQUE SPECIFICATION DRIVESHAFT

Number Designation Model 170 Model 202 Model 208
BA41.10-P-1002-01A Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential. M10 Nm 40 40 40
M12 Nm 60 60 60
BA41.10-P-1003-01A Clamping nut of propeller shaft Nm - 40 -
TORQUE SPECIFICATION PROPELLER SHAFT INTERMEDIATE BEARING

Number Designation Model 170 Model 202 Model 208
BA41.40-P-1001-01A Bolt driveshaft center bearing to frame Bolt with washer Nm 25 25 25
Bolt with collar and self-centering tip Nm 30 30 30
Bolt with collar and without self-centering tip Nm - - -
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 202.018/020/022/120/121/125, with (Code 211) ASD 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 Model 202.018/078/120/121/122/125/182, without (Code 211) ASD, with (Code 450) Taxi equipment
BF35.31-P-1001-01D Filling capacity Rear axle differential Liters 1,1 0.7 1,1
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 202.020/022/023/024/025/026/028/029/080/081/082/083/086/087/088/089/128/ 188 without (code 211) ASD, model 202.085 model 202.085 with automatic 5-speed transmission, model 202.134/194 except (code 450) taxi version Model 202.033/093/133/193 model 202.085 with 5-speed manual transmission, model 202.134/194 with (code 450) Taxi version
BF35.31-P-1001-01D Filling capacity Rear axle differential Liters 1,1 1,1
Specifications for Operating Fluids Sheet BB00.40-P-0235-00A -
Sheet BB00.40-P-0235-07A BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 170.435 Model 170.444/445/447/449 Model 170.465/466
BF35.31-P-1001-01F Filling capacity Rear axle differential Liters 0.7 1,1 1,1
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A BB00.40-P-0235-07A BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 208.335/344/345/347/348/435/444/445/447/448 Model 208.365/370/465/470 Model 208.374/474
BF35.31-P-1001-01H Filling capacity Rear axle differential Liters 1,1 1,1 1,6
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A BB00.40-P-0235-07A BB00.40-P-0235-07A
Fig 2: Identifying Open End Wrench (126 589 00 01 00)
G04713465
Fig 3: Identifying Open End Wrench (201 589 00 01 00)
G04713466
Fig 4: Identifying Assembly Attachment (140 589 01 62 00)
G04713467
REPAIR MATERIALS

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