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Home >> Mercedes Benz >> 2002 >> C32 >> Repair and Diagnosis >> Suspension >> Rear Suspension >> Rear Axle -- Testing & Repair -- 203 Chassis - 1 Of 2 >> Testing & Repair >> Remove/install rear axle differential - AR35.31-P-0520P

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

MODEL 203.004 /204 Rear axle differential dia. 185 except CODE (450) Taxi version 

MODEL 203.035 /045 /061 /235 /245 /261 /735 /745 /747 Rear axle differential dia. 185 

MODEL 203.006 /008 /064 /206 /208 /264 /706 /708 /764, 209.365 /465 Rear axle differential dia. 198 

MODEL 203.016 /065 /216 /265, 209.316, 209.375 /376 /475 /476 up to 23.4.04 Rear axle differential dia. 210 Rear axle differential 210E 

MODEL 203.007 /081 /084 /087 /092 /207 /281 /284 /287 /292 /707, 209.341 /342 /343 /361 /441 /442 /461 Rear axle center assembly dia. 187 

MODEL 203.004 /007 /204 /207 Rear axle differential dia. 198 with CODE (450) Taxi version 

MODEL 203.008 /208 /708, 209.308 Rear axle differential dia. 200 

MODEL 203.007 /207 Rear axle center assembly dia. 200 with CODE (450) Taxi version 

Fig 1: Identifying Rear Axle Differential Remove/Install Components - Shown On Rear Axle Differential Dia. 185 mm In Model 203
G04734729
Fig 2: Identifying Rear Axle Differential Remove/Install Components - Shown On Rear Axle Differential Dia. 198 mm In Model 203
G04734730
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 lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
NOTES Notes on self-locking nuts and bolts All models AH00.00-N-0001-01A
1 Lift/jack up vehicle   AR00.60-P-1000P
2 Remove exhaust heat shield (105c)    
3 Remove bolts from propeller shaft intermediate bearing (106a) TORQUE SPECIFICATION *BA41.40-P-1001-01A 
    SPECIAL TOOL Figure
4 Remove rear propeller shaft (106) from rear axle differential (50) IMPORTANT The flexible coupling remains on the rear propeller shaft (106).
IMPORTANT If the fitting sleeves are jammed:
↓		 AR41.10-P-0050-03EA
    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
    IMPORTANTInstallation:  Attach rear propeller shaft (106) to rear differential assembly (50). AR41.10-P-0050-04EA
    TORQUE SPECIFICATION *BA41.10-P-1002-01A 
    SPECIAL TOOL Figure
5.1 Remove rear axle shaft (37) on right. Rear axle shaft (37), plug-in design:  
    Model 203.065 /265 with rear axle differential 210E AR35.30-P-0620PF 
    Model 203.004 /204 with rear axle differential diameter 185 except taxi version, code 450, Model 203.007 /207 with rear axle differential diameter 198 with taxi version, code 450, Model 203.007 /207 with rear axle differential diameter 200 with taxi version, code 450, Model 203.035 /045 /061 /235 /245 /261 /735 /745 /747 with rear axle differential diameter 185,
Model 203.007 /081 /084 /087 /092 /207 /281 /284 /287 /292 /707 with rear axle differential diameter 187,
Model 209.341 /342 /343 /361 /441 /442 /461 with rear axle differential diameter 187, Model 203.008 /064 /208 /264 /708 /764, 209.365 /465 with rear axle differential 198, Model 209.375 /376 /475 /476 with rear axle differential diameter 210E up to 23.4.04, Model 203.008 /208 /708, model 209.308 with rear axle differential diameter 200		 AR35.30-P-0620P 
5.2 Remove left and right rear axle shafts (37) from rear axle shaft flange Rear axle shaft (37), bolt-on design:  
    Model 203.004 /204 with rear axle differential diameter 198 with taxi version, code 450, Model 203.016 /216, 209.3 /4 with rear axle differential diameter 210E, Model 203.006 /206 /706 with rear axle differential diameter 198 AR35.30-P-0620A
6 Support rear axle differential (50) IMPORTANT Secure against falling.  
    SPECIAL TOOL Figure
7 Unscrew bolts (50a) of rear hangers from rear axle differential (50) TORQUE SPECIFICATION *BA35.10-P-1004-01A 
    SPECIAL TOOL Figure
8 Unscrew bolt (53) of the front mounting from rear axle center assembly (50) IMPORTANTInstallation:  Mount front hanger. AR35.10-P-0050-01A 
    TORQUE SPECIFICATION *BA35.10-P-1003-01A 
    SPECIAL TOOL Figure
9 Lower rear axle differential (50) Rear axle shaft (37), plug-in design:  
    Model 203.007 /207 /707 with rear axle differential diameter 187, Model 203.008 /208 /708 with rear axle differential diameter 198,
Model 203.007 /207 with rear axle differential diameter 198 with taxi version, code 450,
Model 203.007 /207 with rear axle differential diameter 200 with taxi version, code 450, Model 203.008 /208 /708, 209.308 with rear axle differential diameter 200		 AR35.30-P-0620-02PA
    Model 203.004 /204 with rear axle differential diameter 185 except taxi version, code 450, Model 203.035 /045 /061 /235 /245 /261 /735 /745 /747 with rear axle differential diameter 185,
Model 203.081 /084 /281 /284 with rear axle differential diameter 187, Model 203.087 /092 /287 /292, with rear axle differential diameter 187, Model 209.341 /342 /343 /361 /441 /442 /461 with rear axle differential diameter 187,
Model 203.064 /264 /764, 209.365 /465 with rear axle differential diameter 198, Model 203.065 /265, 209.375 /376 /475 /476 with rear axle differential diameter 210E		 AR35.30-P-0620-02PA
    Model 203.007 /207 with rear axle differential diameter 187 with taxi version code 450
IMPORTANT In the process pull the left rear axle shaft (37) out of the rear axle differential (50). Rear axle shaft (37), bolt-on design:
Model 203.004 /204 with rear axle differential diameter 198 with taxi version, code 450, Model 203.006 /206 /706, 209.365 /465 with rear axle differential diameter 198,
Model 203.016 /216, 209.3 /4 with rear axle differential diameter 210E		  
10 Replace breather NOTES Make sure that dirt does not penetrate the breather housing opening, to avoid damage to the interior of the rear axle differential (50).
IMPORTANT Clean housing surface around the breather before removal using suitable cleaning agent. Rear axle differential diameter 185, 198, 210:
Remove breather from rear axle differential (50).		  
    TORQUE SPECIFICATION *BA35.31-P-1003-02B 
    SPECIAL TOOL Figure
    Rear axle differential diameter 187, 200:
Drive breather evenly out of housing using suitable tool (e.g. drift, screwdriver).
IMPORTANT Installation: Drive the new breather evenly into the housing using a suitable drift; make sure that the breather is seated correctly.		  
11 Install in the reverse order    
12 Check oil level in rear axle differential (50) and correct if necessary IMPORTANT In the interest of better fuel economy, avoid mixing old universal hypoid gear oil with new FE hypoid gear oil.
IMPORTANT New oil filling/oil drain screws should be used with rear axle differential diameter 185, 187, 198, 210 up to production date 18.1.04.		 AR35.31-P-0520-03I 
REFER TO COMPONENT MODIFICATIONS Oil filler/drain screw on rear axle differential modified up to 18.1.04 BT35.31-P-0015-01A
REFER TO CAPACITIES & SPECIFICATIONS Universal hypoid gear oils (SAE 85 W-90) Sheet 235.7 BB00.40-P-0235-07A
    IMPORTANT *BA35.31-P-1001-02B 
    FLUID SPECIFICATION *BF35.31-P-1001-01K 
    SPECIAL TOOL Figure
    Loctite 7063 cleaning spray (150 ml) *BR00.45-Z-1046-04A 
    Omnifit sealing compound 100H (50 g) *BR00.45-Z-1061-01A 
TORQUE SPECIFICATION REAR AXLE CARRIER

Number Designation Model 203 Model 209
BA35.10-P-1003-01A Self-locking nut, rear axle differential at front to rear axle carrier Nm 45 43
BA35.10-P-1004-01A Self-locking bolt, rear axle differential at rear to rear axle carrier Nm 110 110
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 203.042/043/046/081/084/087/092/242/246/281/284/287/292/740/742/746, Model 203.004/061/204/261 as of 09/2002
BA35.31-P-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1003-02B Breather, rear axle center assembly Nm 25
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 203.035/045/235/245/735/745/747, 203.061/261 up to 08/2002, Model 203.004/006/204/ 206/706 up to 08/2002
BA35.31-P-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1003-02B Breather, rear axle center assembly Nm 25
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 203.006/007/008/064/206/207/208/264/706/707/708/764, Model 203.004/204 with code 450 up to 08/2002 Model 203.007/207/with code 450
BA35.31-P-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1003-02B Breather, rear axle center assembly Nm 25
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 203.016/216
BA35.31-P-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1003-02B Breather, rear axle center assembly Nm 25
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 203.018/065/218/265/718
BA35.31-P-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1003-02B Breather, rear axle center assembly Nm 25
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 209.341/342/343/361/441/442/461
BA35.31-P-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1003-02B Breather, rear axle center assembly Nm 25
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 209.308/320/354/356/420/454/456
BA35.31-P-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1003-02B Breather, rear axle center assembly Nm -
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 209.316, Model 209.375/376/475/476 up to 23.4.04
BA35.31-P-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1003-02B Breather, rear axle center assembly Nm 30
TORQUE SPECIFICATION DRIVESHAFT

Number Designation Model 203 Model 209
BA41.10-P-1002-01A Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential. M10 Nm 40 36
M12 Nm 60 58
TORQUE SPECIFICATION PROPELLER SHAFT INTERMEDIATE BEARING

Number Designation Model 203 Model 209
BA41.40-P-1001-01A Bolt, propeller shaft intermediate bearing to frame floor assembly Self-tapping screw Nm - -
Bolt with washer Nm - -
Bolt with collar and self-centering tip Nm 30 30
Bolt with collar and without self-centering tip Nm - -
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 203.006/008/054/056/064/206/208/254/256/264/706/708/756/764, Model 203.004/204 with taxi version code 450, up to 08/2002, Model 203.007/207 with taxi version code 450 Model 203.040/042/043/046/052/081/084/087/092/240/242/243/246/252/281/284/287/292/707/730/740/742/743/746, Model 203.004/061/204/261, as of 09/2002, Model 203.007/207 without taxi version
BF35.31-P-1001-01K Filling capacity Rear axle differential Liters 1.1 1.0
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 203.035/045/235/245/735/745/747, Model 203.061/261 up to 08/2002, Model 203.004/204 except code 450 up to 08/2002 Model 203.016/216 Model 203.018/065/218/265/718
BF35.31-P-1001-01K Filling capacity Rear axle differential Liters 1.1 1.6 1.6
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 209.341/342/343/361/441/442/461 Model 209.308/354/356/365/454/456/465 Model 209.316, Model 209.375/376 475/476 up to 23.4.04
BF35.31-P-1001-01K Filling capacity Rear axle differential Liters 1.0 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 Assembly Attachment (140 589 01 62 00)
G04734731
Fig 4: Identifying Torque Wrench (001 589 66 21 00)
G04734732
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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