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Removing and installing complete rear axle - AR35.10-P-0010B

MODEL 210 

Fig 1: Identifying Complete Rear Axle Remove/Install Components - Model 210
G04636211
Fig. item, etc. Work instructions    
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
DANGER Risk of injury  to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning  from swallowing hydraulic fluid. Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses. AS00.00-Z-0013-01A
IMPORTANT Rear struts, removal and installation Vehicles with level control AR32.25-P-1016A
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
IMPORTANT Remove/install rear spring Remove both rear springs. AR32.20-P-0230A
IMPORTANT Remove/install rear shock absorber Vehicles without level control AR32.25-P-0110A
IMPORTANTInstallation  Check oil level in rear axle center assembly 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 center assembly *BF35.31-P-1001-01E 
    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 center assembly *BA35.31-P-1002-02A 
REFER TO COMPONENT MODIFICATIONS Oil filler and drain screw on rear axle center assembly modified as of 19.01.04 BT35.31-P-0015-01A
IMPORTANTInstallation  Check vehicle level at rear axle.   AR40.20-P-0300C
IMPORTANTInstallation  Check headlamp setting and correct if necessary    
SPECIAL TOOL Assembly attachment   Fig 2
SPECIAL TOOL Guard plate   Fig 3
1c Front rear final drive mounting bolt NOTESInstallation:  recut thread on frame floor with tap.  
    TORQUE SPECIFICATION *BA35.10-P-1001-01A 
1d Rear final drive mounting bolt NOTESInstallation:  Recut thread on frame floor with tap.  
    TORQUE SPECIFICATION *BA35.10-P-1002-01A 
6k Stabilizer bar linkage rod TORQUE SPECIFICATION *BA32.20-P-1001-04D 
105 Remove / install exhaust system as from flange connection See ↓
Remove complete exhaust system		  
    Engine 104, 604, Model 210.0 with Engine 111, 605, Model 210.020 with engine 606 AR49.10-P-7000B
    Model 210.2 with engine 111, 602, 605, 606 AR49.10-P-7000BA
    Engine 112, 113 AR49.10-P-7000A
    Engine 119 AR49.10-P-7000EA
    Model 210.0 with engine 602, Model 210.025 with engine 606 AR49.10-P-7000C
    Engine 611, 612, 613 AR49.10-P-7000HB
106 REFER TO SHOP-MADE TOOLS Driveshaft rear section IMPORTANT Flexible disk remains on propeller shaft.  
    Loosen fitted sleeves on flexible couplings. AR41.10-P-0050-09DA
    Drift for loosening fitted sleeves in flexible couplings. WF58.50-P-4110-01A
    TORQUE SPECIFICATION *BA41.10-P-1002-01A 
106 A Propeller shaft intermediate bearing IMPORTANTInstallation:  Only tighten the bolts of the propeller shaft intermediate bearing after attaching the flexible coupling to the rear axle center assembly.  
    TORQUE SPECIFICATION *BA41.40-P-1001-01A 
110 B Parking brake cables from automatic cable adjuster or idler lever, releasing and attaching See ↓  
    Remove/install rear brake control cable AR42.20-P-0525A
DANGER Risk of poisoning  caused by swallowing brake fluid. Risk of injury  caused by brake fluid coming into contact with skin and eyes. Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. AS42.50-Z-0001-01A
111e Brake hose COMMERCIALLY AVAILABLE TOOLS Detach brake hose at frame floor. *WH58.30-Z-1003-11A 
    NOTES Seal line connections immediately with plugs. The brake fluid reservoir must not be allowed to empty completely.
NOTESInstallation:  The brake hoses (111e) must not be twisted after being tightened (risk of cracking).		  
    TORQUE SPECIFICATION Brake line at brake hose *BA42.10-P-1001-04A 
    NOTESInstallation:  Bleed brake system AR42.10-P-0010A
NOTES Brake fluid notes   AH42.50-P-0001-01A
NOTES Notes on installing brake hoses   AH42.10-P-9406-01A
IMPORTANT Notes on repairs to brake system   AH42.00-P-0003-01A
140 Shield on fuel pump assembly    
X62/1 Left rear axle VSS [GES] sensor / brake pad contact sensor connector Beneath rear seat on left  
X62/2 Right rear VSS [GES] sensor / brake pad wear sensor connector Beneath rear seat on right  
TORQUE SPECIFICATION Rear axle torsion strut

Number Designation Model 210 with ride-height control/ADS CODE 217 Model 210 without ride-height control/ADS CODE 217
BA32.20-P-1001-04D Self-locking nuts of torsion bar link rod to spring link Nm 20 20
TORQUE SPECIFICATION Rear axle carrier

Number Designation Model 210
BA35.10-P-1001-01A Self-locking bolt, front rear axle carrier rubber mount to frame floor     Nm 90
with bolt 1st stage Nm -
flange ø 24 mm 2nd stage ∠° -
with bolt 1st stage Nm -
flange ø 26 mm 2nd stage ∠° -
BA35.10-P-1002-01A Self-locking bolt, rear axle carrier rear rubber mount to frame floor     Nm 90
with bolt 1st stage Nm -
flange ø 24 mm 2nd stage ∠° -
with bolt 1st stage Nm -
flange ø 26 mm 2nd stage ∠° -
TORQUE SPECIFICATION Rear axle center assembly housing

Number Designation Model 210
BA35.31-P-1002-02A Oil filler plug, rear axle center assembly Nm 50
TORQUE SPECIFICATION Driveshaft

Number Designation Model 210
BA41.10-P-1002-01A Self-locking nut, flexible coupling to rear propeller shaft or rear axle center assembly. M10 Nm 40
M12 Nm 60
TORQUE SPECIFICATION Driveshaft center bearing

Number Designation Model 210.0/2 Model 210.6
BA41.40-P-1001-01A Bolt driveshaft center bearing to frame Bolt with washer Nm - -
Bolt with collar and self-centering tip Nm 30 -
Bolt with collar and without self-centering tip Nm - 25
TORQUE SPECIFICATION Brake lines, brake hoses

Number Designation Model 210
BA42.10-P-1001-04A Brake line to brake hose Nm 14
FLUID SPECIFICATION Rear final-drive unit

Number Designation Models 210.003/004 except Code 450 Model 210.010/020/035/037/048/061/062/210/235/237/248/261/262/610 Model 210.006/015/017/025/045/053/055/063/065/08/206/215/217/225/245/263/265/28/606/663, 210.007 with code 450
BF35.31-P-1001-01E Filling capacity Rear axle center assembly 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 final-drive unit

Number Designation Model 210.070/074/270/274 up to 31.01.98, 210.072/272/617 Model 210.003/004 with code 450, 210.007 except code 450 Model 210.070/074/270/274 as of 01.02.98, 210.016/026/216/226/616
BF35.31-P-1001-01E Filling capacity Rear axle center assembly Liters 1.3 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 Assembly Attachment (140 589 01 62 00)
G04636212
Fig 3: Identifying Guard Plate (220 589 01 31 00)
G04636213
Commercially available tools

Number Designation
WH58.30-Z-1003-11A Open double end box wrench a/f 8x9 mm or a/f 10x11 mm
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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