Remove/install complete rear axle - AR35.10-P-0010D

MODEL 170, 202, 208 

Fig 1: Identifying Rear Axle Remove/Install Components (1 Of 2)

Fig 2: Identifying Rear Axle Remove/Install Components (2 Of 2)

MODIFICATION NOTES

20.3.04	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04 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 differential. 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	Only carry out oil level check at interior temperature.	AR35.31-P-0520-03A
20.3.04	The vehicle must have a chassis alignment check after the rear axle is installed

Fig. item, etc.	Work instructions
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
Installation	Bleed ASD hydraulic system	Model Series 202 with ASD up to 05/94	AR35.41-P-0519C
Installation	Check vehicle level at rear axle		AR40.20-P-0300A
Installation	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
		Model 170	*BF35.31-P-1001-01F
		Model 202	*BF35.31-P-1001-01D
		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
		Oil filler plug	*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
Installation	Perform a wheel alignment check		AR40.20-P-0200A
Installation	Check headlamp adjustment and correct if necessary
	Check and correct headlamp adjustment		AP82.10-P-8260A
	Assembly attachment		Fig 5
	Guard plate		Fig 6
1c	Front rear final drive mounting bolt	Installation:  Recut thread on frame floor with tap.
			*BA35.10-P-1001-01A
1d	rear final drive mounting bolt	Installation:  Recut thread on frame floor with tap.
			*BA35.10-P-1002-01A
6 g	Spring control arm covering
6i	Remove/install rear spring	Remove both rear springs.	AR32.20-P-0230A
	Risk of injury  to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning  caused by 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
6j	Detach dampers or suspension struts from the spring control arms
		Vehicles without ride-height control.	*BA32.25-P-1003-03A
		Vehicles with ride-height control.	*BA32.30-P-1003-01B
6k	Stabilizer bar link rod		*BA32.20-P-1002-04C
36	Detach both frame cross struts	Model 170 only	*BA61.10-P-1001-01A
		Model 208.4 only	*BA61.10-P-1003-01C
105	Remove / install exhaust system from flange connection	Refer to: Remove/install exhaust system 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, 208 with engine 112, 113	AR49.10-P-7000AU
		Model 208 with engine 111	AR49.10-P-7000DA
105c	Exhaust shielding plate
106	Remove rear of driveshaft at joint flange	Flexible disk remains on propeller shaft.
		Loosen fitting sleeves on flexible couplings.	AR41.10-P-0050-09DA
		Drift for loosening fitting sleeves in flex disks. Fit on propeller shaft at stiffener arm.	WF58.50-P-4110-01A
			*BA41.10-P-1002-01A
106a	Propeller shaft intermediate bearing	Installation:  Only tighten the bolts of the propeller shaft intermediate bearing after attaching the flexible coupling to the rear axle differential.
			*BA41.40-P-1001-01A
106c	Propeller shaft clamp nut	Model 202 up to approx. 10/95
		Open-end wrench 46 mm	Fig 3
		Open-end wrench 41 mm	Fig 4
			*BA41.10-P-1003-01A
	Clamp connection of propeller shaft	Model 202:	BT41.10-P-9110-01DA
		Converted to flexible connection.
110b	Parking brake cables from automatic cable adjuster or idler lever, releasing and attaching	See: ↓
		Remove/install rear brake control cable	AR42.20-P-0525A
	Risk of poisoning  caused by swallowing brake fluid. Risk of injury  caused by brake fluid coming into contact with skin and eyes	Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.	AS42.50-Z-0001-01A
111e	Brake hose	Detach brake hose from floorpan.
		Seal line connections immediately with plugs. The brake fluid reservoir must not run completely empty.
		Box-end wrench attachment	Fig 7
		Installation:  The brake hoses (111e) must not be twisted after being tightened (danger of cracking).
			*BA42.10-P-1001-04A
		Installation:  Bleed brake system	AR42.10-P-0010A
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on installing brake hoses		AH42.10-P-9406-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
115	Remove fuel pump assembly from rubber rings and tie into place with wire
140	Shield on fuel pump assembly
a	Disconnect, connect 2-pin fuel pump wiring harness connector
		Engines 104, 111	AR47.20-P-5713D
HS	Hydraulic line	Only Model 202 to 05/94 with ASD Removal:  Plug threaded sockets on ring cylinder and line.
L6	Rear axle rpm sensor	Vehicles with ABS: Clean magnetic tip, replace O-ring.	ra42001240714x
L6/3, L6/4	Remove/install left rear rpm sensor and right rear rpm sensor	Vehicles with ASR up to 05/94	ra42002020820x
		Vehicles with ASR, ETS, ESP as of 06/94	AR42.40-P-0820A
X33/17	Rear headlamp range adjustment connector	Model 170: Vehicles with Xenon headlamps
X33/17	Rear ADS/headlamp range adjustment connector	Models 202, 208: Vehicles with Xenon headlamps
X62/1, X62/2	Left rear rpm sensor / brake wear indicator connector	If installed
X62/11	Rear axle ABS rpm sensor connector (2-pin)	If installed

REAR AXLE STABILIZER BAR

Number	Designation		Model 170	Model 202 without level adjustment	Model 202 with ride-height control
BA32.20-P-1002-04C	Self-locking nut, linkage rod to track control arm	Nm	20	20	20

REAR AXLE STABILIZER BAR

Number	Designation		Model 208 without level control	Model Series 208 with level control system
BA32.20-P-1002-04C	Self-locking nut, linkage rod to track control arm	Nm	20	20

SUSPENSION STRUT REAR AXLE

Number	Designation		Model 202 with level control	Model 208 with level control
BA32.30-P-1003-01B	Self-locking nut, ride-height control strut to track control arm	Nm	55	55

REAR AXLE SHOCK ABSORBER

Number	Designation			Model 170	Model 202	Model 208
BA32.25-P-1003-03A	Self-locking nut for attaching shock absorber to spring control arm		Nm	55	55	55
		M10	Nm	-	-	-

REAR AXLE CARRIER

Number	Designation				Model 170	Model 202	Model 208
BA35.10-P-1001-01A	Self-locking bolt, front rear axle carrier rubber mount to frame floor			Nm	90	90	90
		with ø 24mm bolted flange	Stage 1	Nm	-	-	-
		with ø 26mm bolted flange	Stage 2	∠ °	-	-	-
			Stage 1	Nm	-	-	-
			Stage 2	∠ °	-	-	-
BA35.10-P-1002-01A	Self-locking bolt, rear axle carrier rear rubber mount to frame floor			Nm	90	90	90
		with ø 24mm bolted flange	Stage 1	Nm	-	-	-
		with ø 26mm bolted flange	Stage 2	∠ °	-	-	-
			Stage 1	Nm	-	-	-
			Stage 2	∠ °	-	-	-

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

REAR AXLE CENTER ASSEMBLY HOUSING

Number	Designation		Model 208
BA35.31-P-1002-02A	Oil filler screw, rear axle differential	Nm	50

PROPELLER SHAFT

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	-

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	-	-	-

BRAKE LINES, BRAKE HOSES

Number	Designation		Model 170	Model 202	Model 208
BA42.10-P-1001-04A	Brake pipe to brake hose	Nm	14	14	14

FRAME FLOOR ASSEMBLY

Number	Designation		Model 170
BA61.10-P-1001-01A	Self-locking bolt connecting rear cross strut to frame floor	Nm	60

FRAME FLOOR ASSEMBLY

Number	Designation		Model 208.435/445/447/465/470
BA61.10-P-1003-01C	Self-locking bolt connecting rear cross strut to frame floor	Nm	60

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 center assembly	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

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 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 center assembly	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

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 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

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 center assembly	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 3: Identifying Open End Wrench (126 589 00 01 00)

Fig 4: Identifying Open End Wrench (201 589 00 01 00)

Fig 5: Identifying Assembly Attachment (140 589 01 62 00)

Fig 6: Identifying Guard Plate (220 589 01 31 00)

Fig 7: Identifying Box Wrench Bit (000 589 75 03 00)

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