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Home >> Mercedes Benz >> 2002 >> C32 >> Repair and Diagnosis >> Suspension >> Rear Suspension >> Rear Axle -- Testing & Repair -- 203 Chassis - 2 Of 2 >> Testing & Repair >> Remove/install end cover at rear axle differential - AR35.31-P-0554AC

Remove/install end cover at rear axle differential - AR35.31-P-0554AC

Rear axle differential dia. 215 in model 171.473, 203.076 /276, 209.372, 209.375 /376 /476 as of 24.4.04, 209.377 /472, 209.475 as of 24.4.04, 209.477, 211.076 /276 /077 /277, 219.376 /377, 230.472 /474 /479 

Fig 1: Identifying End Cover At Rear Axle Differential Remove/Install Components - Dia. 215
G04734804
MODIFICATION NOTES

10.8.06 Filling capacity, specifications for operating fluids Model 209.377/477 *BF35.31-P-1001-01K 
    Model 219.376/377 *BF35.31-P-1003-01P 
    Model 211.077/277, 230.472/474/479 *BF35.31-P-1004-01L 
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   AH00.00-N-0001-01A
1 Lift/jack up vehicle Model 219 AR00.60-P-1000TX
    Model 171 AR00.60-P-1000V
    Model 203, 209 AR00.60-P-1000P
    Model 211
Model 230		 AR00.60-P-1000T
2 Drain oil from rear axle differential (1) Model 171 AR35.31-P-0520-06V
    Model 203, 209, 211, 230 AR35.31-P-0520-06I
    Model 219 *BA35.31-P-1003-02C 
    TORQUE SPECIFICATION AR35.31-P-0520-06TX
    TORQUE SPECIFICATION *BA35.31-P-1002-02B 
    TORQUE SPECIFICATION *BA35.31-P-1003-02D 
    TORQUE SPECIFICATION *BA35.31-P-1003-02A 
    Loctite cleaning spray *BR00.45-Z-1046-04A 
    Omnifit sealing compound *BR00.45-Z-1061-01A 
3 Unscrew screws (3) on heat sink (4) and remove heat sink (4) IMPORTANT For models 211.076 /276 observe different versions of rear axle center assembly (1)!  
    TORQUE SPECIFICATION *BA35.31-P-1007-02C 
    TORQUE SPECIFICATION *BA35.31-P-1005-02B 
    TORQUE SPECIFICATION *BA35.31-P-1007-02A 
    TORQUE SPECIFICATION *BA35.31-P-1006-02D 
4 Remove rear axle differential (1) NOTES While working on the rear axle care must be taken to ensure that the surface of all aluminum components do not get any scratches, cracks and notches. Otherwise the service life of the of the parts will be reduced.  
    Model 171 AR35.31-P-0520V
    Model 203, 209 AR35.31-P-0520AC
    Model 211 AR35.31-P-0520T
    Model 219 AR35.31-P-0520TX
    Model 230 AR35.31-P-0520R
5 Unscrew bolts on end cover (2) and remove end cover (2) IMPORTANT 8 Screws  
    IMPORTANT Detach the end cover (2) using a suitable tool.  
    TORQUE SPECIFICATION *BA35.31-P-1001-02C 
    TORQUE SPECIFICATION *BA35.31-P-1004-02B 
    TORQUE SPECIFICATION *BA35.31-P-1001-02A 
    TORQUE SPECIFICATION *BA35.31-P-1001-02D 
6 Clean sealing surfaces LU cleaner *BR00.45-Z-1028-04A 
7 Coat sealant on sealing surface IMPORTANT The sealing surfaces on the end cover (2) and rear axle center assembly (1) must be free from oil and grease.
IMPORTANT The sealing compound must be worked on within 10 minutes.		  
    SPECIAL TOOL Figure
    Sealant *BR00.45-Z-1013-01A 
8 Install in the reverse order    
9 Pour oil into the rear axle differential (1) IMPORTANTImportant note:  A special oil must be used for model 230.479.  
    Model 203, 209, 211, 230 AR35.31-P-0520-03I
    Model 171 AR35.31-P-0520-03V
    Model 219 AR35.31-P-0520-03TX
    TORQUE SPECIFICATION *BA35.31-P-1001-02B 
    TORQUE SPECIFICATION *BA35.31-P-1002-02A 
    TORQUE SPECIFICATION *BA35.31-P-1002-02C 
    TORQUE SPECIFICATION *BA35.31-P-1002-02D 
    FLUID SPECIFICATION *BF35.31-P-1001-01K 
    FLUID SPECIFICATION *BF35.31-P-1001-01O 
    FLUID SPECIFICATION *BF35.31-P-1003-01P 
    FLUID SPECIFICATION *BF35.31-P-1004-01L 
    Loctite cleaning spray *BR00.45-Z-1046-04A 
    Omnifit 100H cleaning compound *BR00.45-Z-1061-01A 
INSPECT Check     
10 Check rear axle center assembly (1) for leaks    
TORQUE SPECIFICATION REAR AXLE CENTER ASSEMBLY HOUSING

Number Designation Model 171.473
BA35.31-P-1001-02C Bolt, end cover to rear axle center assembly Bolt+washer Nm -
Flange bolt (TORX, internal serrations) Stage 1 Nm 30
Stage 2 ∠ ° 45
BA35.31-P-1002-02C Oil filler screw, rear axle differential Nm 50
BA35.31-P-1003-02C Oil drain screw, rear axle differential Nm 50
BA35.31-P-1007-02C Bolt, heat sink to end cover Nm 37
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 203.076/276 Model 209.375/376/475/476 as of 24.4.04 Model 209.372/377/472/477
BA35.31-P-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1002-02B Oil drain screw, rear axle differential Nm 50
BA35.31-P-1004-02B Bolt, end cover to rear axle center assembly Bolt+washer Nm -
Flange bolt Stage 1 Nm 30
(TORX, multipoint socket) Stage 2 ∠ ° 45
BA35.31-P-1005-02B Bolt, heat sink to end cover Nm 37
TORQUE SPECIFICATION REAR AXLE CENTER ASSEMBLY HOUSING

Number Designation Model 219
BA35.31-P-1001-02D Bolt, end cover to rear axle center assembly Stage 1 Nm 30
Stage 2 ∠ ° 45
BA35.31-P-1002-02D Oil filler screw, rear axle differential Nm 50
BA35.31-P-1003-02D Oil drain screw, rear axle differential Nm 50
BA35.31-P-1006-02D Bolt, heat sink to end cover Nm 35
TORQUE SPECIFICATION REAR AXLE CENTER ASSEMBLY HOUSING

Number Designation Model 230 Model 211
BA35.31-P-1001-02A Bolt, end cover to rear axle center assembly Bolt+washer Nm - -
Flange bolt (TORX, internal serrations) Stage 1 Nm 30 30
Stage 2 ∠ ° 45 45
BA35.31-P-1002-02A Oil filler screw, rear axle differential Nm 50 50
BA35.31-P-1003-02A Oil drain screw, rear axle differential Nm 50 50
BA35.31-P-1007-02A Bolt, heat sink to end cover Nm 37 35
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 171.473
BF35.31-P-1001-01O Filling capacity Rear axle center assembly Liters 1.2
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 203.020/076/220/276 Model 209.320/420, Model 209.375/376/475/476 as of 24.4.04 Model 209.372/472 Model 209.377/477
BF35.31-P-1001-01K Filling capacity Rear axle center assembly Liters 1.2 1.2 1.2
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A BB00.40-P-0235-07A BB00.40-P-0235-61A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 219 except 219.376/377 Model 219.376/377
BF35.31-P-1003-01P Filling capacity Rear differential assembly dia. 215 mm Liters 1.2 1.2
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A BB00.40-P-0235-61A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 211.077/277, model 230.472/474/479
BF35.31-P-1004-01L Filling capacity Rear differential assembly dia. 215 mm Liters 1.2
Specifications for Operating Fluids Sheet BB00.40-P-0235-61A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 211 except 211.077/277 Model 230 except 230.472/474/479
BF35.31-P-1004-01L Filling capacity Rear differential assembly dia. 215 mm Liters 1.2 1.2
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A BB00.40-P-0235-07A
Fig 2: Identifying Squeeze Gun (112 589 00 25 00)
G04734805
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1061-01A Sealant, Omnifit 100H (50 g) -
BR00.45-Z-1013-01A Sealant A 003 989 98 20
BR00.45-Z-1046-04A Cleaning spray, Loctite 7063 (150ml) A 001 986 71 71 10
BR00.45-Z-1028-04A LU cleaner Adolf Wurth GmbH & Co. KG
Reinhold-Wurth-Str. 12-17
74653 Kunzelsau-Gaisbach
Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
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