 |
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 |
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Notes on self-locking nuts and bolts |
All models |
AH00.00-N-0001-01A |
| 1 |
Raise vehicle |
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AR00.60-P-1000P |
| 2 |
Remove rear wheels. |
For rear axle differentials dia. 185 mm, dia. 198 mm, dia. 210 mm |
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Remove/install wheels, rotate if necessary |
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AP40.10-P-4050Z |
| 3 |
Press back brake pads at fixed calipers of rear axle |
For rear axle differentials dia. 185 mm, dia. 198 mm, dia. 210 mm
Ensure clearance of brake discs. |
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| 4 |
Drain oil from rear axle differential |
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AR35.31-P-0520-06I |
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*BA35.31-P-1002-02B |
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Cleaning spray, Loctite 7063 (150ml) |
*BR00.45-Z-1046-04A |
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Sealant, Omnifit 100H (50 g) |
*BR00.45-Z-1061-01A |
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Oil filler/drain screw on rear axle differential modified |
Phased in as of 19.01.04 |
BT35.31-P-0015-01A |
| 5 |
Remove exhaust system (105) from flange connection |
Refer to Removing complete exhaust system (105): |
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Model 203 with engine 111 |
AR49.10-P-7000PR |
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Model 203 with engine 112
Model 209 with Engine 112, 113 |
AR49.10-P-7000PV |
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Model 203 with engine 611, 612
Model 209 with engine 612 |
AR49.10-P-7000PP |
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Model 203 with engine 271.940 /946 /948
Model 209 with engines 271.940 /955 |
AR49.10-P-7000QK |
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Model 203, 209 with engine 271.942 |
AR49.10-P-7000QD |
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Model 203 with engine 272 |
AR49.10-P-7000QB |
| 6 |
Remove exhaust heat shield (105c) |
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| 7 |
Remove bolts for propeller shaft intermediate bearing (106a). |
Installation:
Only tighten down the bolts of the propeller shaft center support bearing (106a) when the flex disk is installed on the rear axle differential. |
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*BA41.40-P-1001-01A |
| 8 |
Remove rear propeller shaft assembly (106) from rear axle differential. |
The flexible coupling remains on the rear propeller shaft (106). |
AR41.10-P-0050-03EA |
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Installation:
Attach rear driveshaft section (106) to final-drive unit. |
AR41.10-P-0050-04EA |
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*BA41.10-P-1002-01A |
| 9 |
Loosen fitting sleeves on flexible couplings. |
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AR41.10-P-0050-09DA |
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Drift for loosening fitting sleeves in flex disks. |
|
WF58.50-P-4110-01A |
| 10 |
Detach rear propeller shaft (106) from front propeller shaft (106c) |
Installation:
Assemble the driveshaft. |
AR41.10-P-0050-05DA |
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Long-life grease (NLGI grade 2) |
BB00.40-P-0266-02A |
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Measure |
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| 11 |
Measure and note down total friction torque of drive pinion |
For rear axle differentials dia. 185 mm, dia. 198 mm, dia. 210 mm |
AR35.31-P-0530-04P |
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Move the rear axle shafts (37) to as close to horizontal as possible. If necessary, pretension both rear springs with spring compressor. |
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Figure |
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Figure |
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Figure |
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*WH58.30-Z-1013-06A |
| 12 |
Loosen and remove twelve-point collar nut (40) |
On 185 mm dia., 198 mm dia., 210 mm dia. rear axle differentials:
Do not remove collar protection when slackening the twelve-point collar nut (40). |
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Figure |
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Figure |
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Installation:
Replace twelve-point collar nut (40) and tighten in stages until the total friction torque measured previously is reached.
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*BA35.31-P-1001-01A |
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Observe minimum tightening torque on model 203 with 185 mm dia. rear axle differential, replace elastic spacer sleeve if necessary if torque is not attained: ↓
Disassemble/assemble rear axle differential, adjust gear set. |
AR35.31-P-0550C |
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Installation:
Secure twelve-point collar nut (40) |
AR35.31-P-0530-01B |
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Chisel for securing collar nut on joint flange |
WF58.50-P-3531-01A |
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On 187 mm dia. rear axle differential:
Do not remove collar protection when slackening the twelve-point collar nut (40). |
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Figure |
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Figure |
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Installation:
Replace twelve-point collar nut (40).
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*BA35.31-P-1001-01A |
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Installation:
Secure twelve-point collar nut (40). |
AR35.31-P-0530-01B |
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Chisel for securing collar nut on joint flange |
WF58.50-P-3531-01A |
| 13 |
Detach joint flange (41). |
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Figure |
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Radial sealing ring and joint flange on drive pinion modified |
As of 15.01.02 with model 203 with rear axle differential dia. 185 mm |
BT35.31-P-0012-01B |
| 14 |
Press out radial sealing ring (42) with a suitable tool |
Installation:
Replace radial sealing ring (42) and coat the lip with Universal hypoid gear oil. |
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Universal hypoid gear oils (SAE 85 W-90) |
BB00.40-P-0235-07A |
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Drift for pressing in the previous radial sealing ring version for rear axle differential dia. 185 mm. |
Figure |
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Drift for pressing in radial sealing ring for rear axle differential dia. 187 mm |
Figure |
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Radial sealing ring and joint flange on drive pinion modified |
As of 15.01.02 with model 203 with rear axle differential dia. 185 mm |
BT35.31-P-0012-01B |
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Drift for pressing in the new radial sealing ring version for rear axle differential dia. 185 mm. |
Figure |
| 15 |
Install in the reverse order |
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| 16 |
If necessary, replace breather of rear axle differential |
|
*BA35.31-P-1003-02B |
| 17 |
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-0520-03I |
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*BA35.31-P-1001-02B |
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*BF35.31-P-1001-01K |
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Cleaning spray, Loctite 7063 (150ml) |
*BR00.45-Z-1046-04A |
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Sealant, Omnifit 100H (50 g) |
*BR00.45-Z-1061-01A |
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Oil filler/drain screw on rear axle differential modified |
Phased in as of 19.01.04 |
BT35.31-P-0015-01A |