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

MODEL 203.040 /042 /043 /046 /052 /240 /242 /243 /246 /252 /730 /740 /742 /743 /746 Rear axle differential dia. 187

MODEL 203.054 /056 /254 /256 /756, 209.354 /356 /454 /456 Rear axle differential dia. 200

Fig 1: Identifying End Cover At Rear Axle Differential Remove/Install Components - Model 203.054/056/254/256

Fig 2: Identifying End Cover At Rear Axle Differential Remove/Install Components - Shown On 187 mm Dia. Rear Axle Differential

	Remove/install
	Risk of injury to skin and eyes caused by handling hot or glowing objects.	Wear safety gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	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 on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Lift/jack up vehicle		AR00.60-P-1000P
2	Drain oil from rear axle differential (50)		AR35.31-P-0520-06I
	Universal hypoid gear oils (SAE 85 W-90)	Sheet 235.7	BB00.40-P-0235-07A
		Model 203.040/042/043/046/240/242/243/246/740/742/743/746 with rear axle differential 187FE up to production period 18.1.04 ↓
	Oil filler/drain screw on rear axle differential modified	up to 18.1.04	BT35.31-P-0015-01A
		Oil drain screw, rear axle differential	*BA35.31-P-1002-02B
		Torque wrench	Fig 5
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
		Omnifit sealing compound 100H (50 g)	*BR00.45-Z-1061-01A
3	Detach rear exhaust system (2) from rubber mounts (1)	After detaching from the rubber mounts (1), lower the rear exhaust system (2) slightly and prevent it from falling down, otherwise the entire exhaust system could be damaged, deformed or cracked.
		Hook wrench	*WH58.30-Z-1001-19A
4	Remove rear nuts (4) on side underfloor paneling (3)	On both sides, remove only the two rear nuts (4).
5	Remove retaining bracket (6) from stabilizer bar (7).	Both sides.
		Bolt, retaining bracket to stabilizer bar bracket	*BA32.20-P-1006-04C
		Torque wrench	Fig 5
6	Remove rear propeller shaft from rear axle differential	The flexible coupling (57) remains on the rear propeller shaft (106). On fixed fitting sleeves (58), see: ↓	AR41.10-P-0050-03EA
		Loosen fitting sleeves on flexible couplings.	AR41.10-P-0050-09DA
	Drift for loosening fitting sleeves in flexible coupling.	Models 129, 140, 170, 171, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230	WF58.50-P-4110-01A
	Mount rear propeller shaft to rear axle center assembly		AR41.10-P-0050-04EA
		Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential.	*BA41.10-P-1002-01A
		Torque wrench	Fig 5
7	Support rear axle differential (50)	Secure against falling.
		Assembly attachment	Fig 6
		Telescopic transmission jack, 0.5 to 1.0 t	*WE58.40-Z-1030-11A
8	Remove front bolt of rear axle differential (53)	Installation: Observe the tightening torque of the self-locking counternut.
		Self-locking nut, rear axle differential at front to rear axle carrier	*BA35.10-P-1003-01A
		Torque wrench	Fig 5
9	Remove rubber mount (1) with shim from rear axle differential (50).	Note the installation position.
10	Remove rear bolts from rear axle differential (50a)	Self-locking bolts, rear axle differential to rear of rear axle carrier	*BA35.10-P-1004-01A
		Torque wrench	Fig 5
11	Lower rear axle differential (50)	When doing so, slide the input shaft (51) of the rear axle differential (50) out of the rear propeller shaft (106). Lower just enough to allow the bolts of the end cover (56b) to be fitted without obstruction. Installation: Grease the input shaft (51) before connecting it to the rear propeller shaft (106).
		Telescopic transmission jack, 0.5 to 1.0 t	*WE58.40-Z-1030-11A
		Assembly attachment	Fig 6
		Long-life grease	*BR00.45-Z-1001-06A
12	Remove bolts for end cover (56b)	Bolt, end cover to rear axle differential	*BA35.31-P-1004-02B
		Torque wrench	Fig 5
13	Remove the end cover (54).	Detach the end cover (54) using a suitable tool. Installation: Clean sealing surfaces on rear axle differential (50) and end cover (54). The sealing surfaces must be free of oil and grease. Installation: Coat the sealing surface with sealing compound. The sealing compound must be applied within 10 min.
		Sealant	*BR00.45-Z-1013-01A
		LU cleaner	*BR00.45-Z-1028-04A
14	Replace breather (55) on rear axle differential (50)	To prevent damage to the inside, make sure that no dirt enters the housing opening of the rear axle differential (50). Installation: The new breather (55) must be knocked evenly and slowly into the rear axle differential (50), to avoid deformation and damage. Clean rear axle differential (50) on breather (55) with suitable cleaning agent before removal. Evenly drive breather (55) out of rear axle differential (50) with suitable tool (e.g. drift, screwdriver). Installation: Drive new breather (55) into rear axle differential (50) using a suitable drift.
15	Install in the reverse order
16	Pour oil into the rear axle differential (50)	In the interest of better fuel economy, avoid mixing old universal hypoid gear oil with new FE hypoid gear oil.	AR35.31-P-0520-03I
	Universal hypoid gear oils (SAE 85 W-90)	Sheet 235.7 Model 203.040/042/043/046/240/242/243/246/740/742/743/746 with rear axle differential 187FE up to production period 18.1.04 ↓	BB00.40-P-0235-07A
	Oil filler/drain screw on rear axle differential modified	up to 18.1.04	BT35.31-P-0015-01A
		Oil filler screw for rear axle differential	*BA35.31-P-1001-02B
		Filling capacity of rear axle differential	*BF35.31-P-1001-01K
		Torque wrench	Fig 5
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
		Omnifit sealing compound 100H (50 g)	*BR00.45-Z-1061-01A
	Check
17	Check rear axle differential (50) for leaks	Carry out visual inspection.

REAR AXLE STABILIZER BAR

Number	Designation		Model 203	Model 209
BA32.20-P-1006-04C	Bolt, bracket to stabilizer bar bracket.	Nm	30	30

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

REAR AXLE DIFFERENTIAL HOUSING

Number	Designation				Model 203.020/040/052/054/056/220/240/243/252/254/256/730/743/756
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 differential	Bolt+washer		Nm	-
		Flange bolt	Stage 1	Nm	30
		(TORX, multipoint socket)	Stage 2	∠ °	45

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-1002-02B	Oil drain screw, rear axle differential			Nm	50
BA35.31-P-1004-02B	Bolt, end cover to rear axle differential	Bolt+washer		Nm	-
		Flange bolt	Stage 1	Nm	30
		(TORX, multipoint socket)	Stage 2	∠ °	45

REAR AXLE DIFFERENTIAL HOUSING

Number	Designation				Model 209.308/320/354/355/356/357/420/454/455/456/457
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 differential	Bolt+washer		Nm	-
		Flange bolt	Stage 1	Nm	30
		(TORX, multipoint socket)	Stage 2	∠ °	45

PROPELLER SHAFT

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
BA41.10-P-1002-01A		M12	Nm	60	58

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
BF35.31-P-1001-01K	Filling capacity	Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	BB00.40-P-0235-07A

REAR AXLE DIFFERENTIAL

Number	Designation			Model 209.308/354/356/365/454/456/465
BF35.31-P-1001-01K	Filling capacity	Rear axle differential	Liters	1.1
BF35.31-P-1001-01K	Filling capacity	Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A

Fig 3: Identifying Torque Wrench (001 589 66 21 00)

Fig 4: Identifying Assembly Attachment (140 589 01 62 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1001-19A	Hook wrench, Firma Hazet

WORKSHOP EQUIPMENT

WE58.40-Z-1030-11A

Transmission jack

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-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
BR00.45-Z-1046-04A	Cleaning spray, Loctite 7063 (150ml)	A 001 986 71 71 10
BR00.45-Z-1001-06A	Long-life grease	A 000 989 63 51

Fig 5: Identifying Torque Wrench (001 589 66 21 00)

Fig 6: Identifying Assembly Attachment (140 589 01 62 00)