 |
Removing |
|
|
 |
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 below the lifting platform support points specified by the vehicle manufacturer. |
AS00.00-Z-0010-01A |
| 1 |
Raise vehicle with lifting platform |
|
|
| |
|
Model 203 |
AR00.60-P-1000P |
| 2 |
Drain oil from rear axle differential (50) |
Models 129, 140, 170, 202, 208, 210 |
AR35.31-P-0520-06A |
| |
|
Cleaning spray, Loctite 7063 (150ml) |
*BR00.45-Z-1046-04A |
| |
|
Sealant, Omnifit 100H (50 g) |
*BR00.45-Z-1061-01A |
| |
|
Oil drain screw |
*BA35.31-P-1003-02A |
| |
|
Models 203, 220 |
AR35.31-P-0520-06I |
| |
|
Cleaning spray, Loctite 7063 (150ml) |
*BR00.45-Z-1046-04A |
| |
|
Sealant, Omnifit 100H (50 g) |
*BR00.45-Z-1061-01A |
| |
|
Oil drain screw model 203 |
*BA35.31-P-1002-02B |
| |
|
Oil drain screw model 220 |
*BA35.31-P-1003-02A |
 |
Oil filler/drain screw on rear axle differential modified |
Phased in as of 19.01.04 |
BT35.31-P-0015-01A |
| 3 |
Remove rear axle differential (50) |
Model 129 |
AR35.31-P-0520C |
| |
|
Model 140 |
AR35.31-P-0520A |
| |
|
Model 170, 202, 208 |
AR35.31-P-0520D |
| |
|
Model 203, except models 203.004/204 with taxi version, code 450 Model 203.004/204 with taxi version code 450 |
AR35.31-P-0520P |
| |
|
Model 210 |
AR35.31-P-0520B |
| |
|
Model 220 |
AR35.31-P-0520I |
 |
Features, installation survey for rear axle differentials |
Models 129, 140, 170, 202, 208, 210, 220.063/065/083/084/087/165/183/184/ 187 |
GF35.31-P-1000-01A |
 |
Disassemble |
|
|
| 4 |
Clamp rear axle differential (50)
in assembly stand. |
 |
AR35.31-P-0540-06B |
| 5 |
Remove end cover (54) |
|
|
 |
End cover with unmachined sealing surface |
Model 170, 202.193, 208, 210, 220, Model 202.194 with taxi version, code 450 |
BT35.31-P-0014-01A |
| 6.1 |
Detach circlips (30) from both connecting flanges (33) |
Vehicles with rear axle shafts bolted on to the connecting flange |
AR35.31-P-0540-01A |
| 7.1 |
Pull out connecting flanges (33) |
Vehicles with rear axle shafts bolted on to the connecting flange |
|
 |
Radial seal on side of rear axle housing and connecting flange modified |
as of 01.10.01 |
BT35.31-P-0013-01B |
| 8.1 |
Pry off protective ring on connecting flange |
Vehicles with rear axle shafts bolted on to the connecting flange, as of 01.10.01
If a new radial sealing ring is installed for the first time, a new protection ring must also be installed. |
AR35.30-P-0620-05R |
| 9 |
Pry off left and right radial sealing ring (32a) |
|
AR35.31-P-0540-05C |
 |
Radial seal on side of rear axle housing and connecting flange modified |
as of 01.10.01 |
BT35.31-P-0013-01B |
| 10 |
Using
the spreader, remove the left-hand circlip (29) from the rear axle housing |

Mark circlip (29). |
AR35.31-P-0550-01A |
| 11 |
Remove right circlip (29) from rear axle case using spreader |
Mark circlip (29). |
|
| |
|
Pliers for locking ring, inside (dia. 85 -165 mm) |
*WH58.30-Z-1009-02A |
| 12 |
Remove both tapered roller bearing outer races (11a) out of rear axle housing |

Mark tapered roller bearing outer races (11a) |
AR35.31-P-0550-02A |
| 13 |
Take differential (13) out of rear axle housing |
|
AR35.31-P-0550-03A |
| 14 |
Detach both tapered roller bearing inner races (11b) from differential (13) |

Mark tapered roller bearing inner races (11b). |
AR35.31-P-0550-04A |
| 15 |
Loosen and remove retaining bolts (13a) from crown wheel (47a) |
Mark position of ring gear (47a) in relation to differential (13). |
|
| 16 |
Carefully press off crown wheel (47a) from differential (13) |
|
|
| 17 |
Release and unscrew hexagon collar nut (40) on joint flange (41) |

For better control when undoing the hexagon collar nut (40), press a shop-made bush into the commercially available socket wrench bit.↓ |
AR35.31-P-0550-05A |
 |
|
Pressing bush for wrench socket |
WF58.50-P-3531-02A |
| 18 |
Detach joint flange (41). |

If necessary mark joint flange (41) in relation to drive pinion (47). |
AR35.31-P-0550-06A |
 |
Radial sealing ring (42) and joint flange (41) on drive pinion (47) changed |
Model 129, 140, 170, 202, 203, 208, 210, 220.063/065/165 as of 15.01.02 |
BT35.31-P-0012-01C |
| 19 |
Push drive pinion (47) out of rear axle housing |
 |
AR35.31-P-0550-07A |
| 20 |
Using a suitable screwdriver press radial sealing ring (42) out of rear axle case |
|
AR35.31-P-0550-08A |
 |
Radial sealing ring (42) and joint flange (41) on drive pinion (47) changed |
Model 129, 140, 170, 202, 203, 208, 210, 220.063/065/165 as of 15.01.02 |
BT35.31-P-0012-01C |
| 21 |
Remove tapered roller bearing inner race (43d) |
|
|
| 22 |
Remove tapered roller bearing outer races (46b, 43e) out of rear axle housing |
 |
AR35.31-P-0550-09A |
| 23 |
Remove shim (45) |
|
|
| 24 |
Remove spacer sleeve (44) with thrust plates (48) from drive pinion (47) |
|
|
| 25 |
Pull tapered roller bearing inner race (46a) from drive pinion (47) |
 |
AR35.31-P-0550-10A |
 |
Checking |
|
|
| 26 |
Inspect all parts to determine whether they can be reused, replace if necessary |
If the contact surfaces of the connecting and joint flanges show signs of severe galling due to the radial sealing ring, the flanges must be replaced. |
|
| 27.1 |
Check drive pinion (47) and ring gear (47a) for match-up number |
Model 129, 140, 170, 202, 208, 210 up to 30.06.95
Only lapped gear assemblies up to approx. 06/95 have a match-up number. Each lapped gear set is checked for the best possible smooth running and marked with a consecutive match-up number that is marked on both parts |
AR35.31-P-0550-11A |
 |
Ground ring gear and pinions |
Phased in as of 06/95 |
BT35.31-P-0011-01B |
 |
Assembly, adjusting ring gear and pinion |
|
|
| 28 |
Press tapered roller bearing inner race (46a) onto drive pinion (47) |
|
AR35.31-P-0550-12A |
 |
Press-on sleeve for tapered roller bearing-inner race (46a) of drive pinion gear (47) |
|
WF58.50-P-3531-03A |
| 29 |
Calculate shim (45) and installing in rear axle housing   |
Use data sheet: ↓ Data sheet, Adjusting rear axle gear set: Order No. B20.800.98.113.00C |
AR35.31-P-0550-13A |
| 30 |
Pull tapered roller bearing outer races (43e, 46b) into rear axle housing |
 |
AR35.31-P-0550-14A |
| 31 |
Install spacer sleeve (44) on drive pinion (47) with double-sided thrust plates (48) |
Always replace spacer sleeve (44) and thrust plates (48). |
AR35.31-P-0550-26A |
| 32 |
Insert drive pinion (47) into rear axle housing. |

Support drive pinion (47) with removal and installation tool. |
AR35.31-P-0550-15A |
| 33 |
Place tapered roller bearing inner race (43d) onto drive pinion gear (47) and press in together with radial sealing ring (42) |

Replace radial sealing ring (42) and coat the lip with universal hypoid gear oil. |
AR35.31-P-0550-16A |
 |
Universal hypoid gear oils (SAE 85 W-90) |
|
BB00.40-P-0235-07A |
 |
Radial sealing ring (42) and joint flange (41) on drive pinion (47) changed |
Model 129, 140, 170, 202, 203, 208, 210, 220.063/065/165 as of 15.01.02 |
BT35.31-P-0012-01C |
| 34 |
Slide joint flange (41) onto drive pinion (47) |
Possibly observe applied marking. Coat contact face for radial sealing ring with universal hypoid gear oil. |
|
 |
Universal hypoid gear oils (SAE 85 W-90) |
|
BB00.40-P-0235-07A |
 |
Radial sealing ring (42) and joint flange (41) on drive pinion (47) changed |
Model 129, 140, 170, 202, 203, 208, 210, 220.063/065/165 as of 15.01.02 |
BT35.31-P-0012-01C |
| 35 |
Screw on hexagon collar nut (40) |
Install new collared hexagon nut (40). |
|
| |
|
Socket |
*WH58.30-Z-1013-06A |
| 36 |
Adjust friction torque on drive pinion bearing |
 |
AR35.31-P-0550-17A |
| 37 |
Check adjustment dimension for drive pinion (47) |
 |
AR35.31-P-0550-18A |
| 38 |
Secure hexagon collar nut (40) at joint flange (41) |
|
AR35.31-P-0550-29A |
 |
Chisel for securing hexagon collar nut (40) on joint flange (41). |
|
WF58.50-P-3531-01A |
| 39 |
Dismantling and assembling differential (13) |
 |
AR35.31-P-0560A |
| 40 |
Mount ring gear (47a) onto differential (13) |

Observe marking applied to ring gear (47a) and differential (13). |
AR35.31-P-0550-19A |
| 41 |
Press tapered roller bearing inner races (11b) onto differential (13) |
 |
AR35.31-P-0550-20A |
| 42 |
Install differential (13) in rear axle housing |
|
AR35.31-P-0550-03A |
| 43 |
Insert right tapered roller bearing outer race (11a) in rear axle housing |
 |
AR35.31-P-0550-21A |
| 44 |
Insert right circlip (29) |

Install the circlip (29) removed and marked previously in order to achieve a basic pretension of the rear axle housing. |
AR35.31-P-0550-22A |
| 45 |
Insert left tapered roller bearing outer race (11a) into rear axle housing |
Assembly mandrel
Tapered roller bearing outer race (11a) must contact the tapered roller bearing inner race (11b). |
Figure |
| 46 |
Remove
both assembly mandrels from differential (13) |
|
|
| 47 |
Pre-tension (spread) rear axle housing
with spreader |
 |
AR35.31-P-0550-23A |
| 48 |
Insert left circlip (29) |

Install the circlip (29) removed and marked previously in order to achieve a basic pretension of the rear axle housing. |
AR35.31-P-0550-27A |
| 49 |
Release rear axle housing |
|
|
| 50 |
Measure expanded dimension of rear axle housing |
 |
AR35.31-P-0550-24A |
| 51 |
Measure gear backlash between drive pinion (47) and ring gear (47a), correct if necessary. |

The adjustment of the tapered roller bearing and the gear set are OK, when the spreading dimension (widening) of the rear axle housings and the gear backlash are within the nominal values. This prevents damage to the teeth of the drive pinion gear (47) and the ring gear (47a). |
AR35.31-P-0550-25A |
| 52 |
Remove spreader from rear axle housing |
|
|
| 53 |
Press radial sealing rings (32a) into rear axle housing |

Replace radial sealing ring (32a) and coat the lip with Universal hypoid gear oil. |
AR35.31-P-0540-05C |
 |
Universal hypoid gear oils (SAE 85 W-90) |
|
BB00.40-P-0235-07A |
| 54.1 |
Press protection ring onto connecting flange |
Vehicles with rear axle shafts bolted on to the connecting flange, as of 01.10.01
The protection ring must be mounted when replacing the radial sealing ring for the first time. This is the only way to ensure a proper seal. |
AR35.30-P-0620-05R |
| 55.1 |
Insert connecting flange (33) into differential (13) |
Vehicles with rear axle shafts bolted on to the connecting flange |
|
 |
Radial seal on side of rear axle housing and connecting flange modified |
as of 01.10.01 |
BT35.31-P-0013-01B |
| 56.1 |
Install circlips (30) on both connection flanges (33) |
Vehicles with rear axle shafts bolted on to the connecting flange

Replace circlip (30). |
AR35.31-P-0540-01A |
| 57.1 |
Check axial play of connection flange (33), adjust if necessary |
Vehicles with rear axle shafts bolted on to the connecting flange |
AR35.31-P-0540-02C |
| 58 |
Attach end cover (54) |
If a replacement end cover is fitted, be sure to check whether or not the sealing surface is machined. Use suitable sealant. |
|
| |
|
End cover (54) with machined sealing surface in model 129, 140 Model 202, 208, 210, 220 up to 22.05.00 |
AR35.31-P-0550-28A |
| |
|
Sealant |
*BR00.45-Z-1010-01A |
| |
|
End cover (54) with unmachined sealing surface in model 170, 203, 220.067/083 /084/087/167/183/184/187 Model 202.193/194, 208, 210, 220.063/065/165 as of 23.05.00 |
AR35.31-P-0550-28AA |
| |
|
Sealant |
*BR00.45-Z-1013-01A |
 |
End cover with unmachined sealing surface |
Model 170, 202.193, 208, 210, 220, Model 202.194 with taxi version, code 450 |
BT35.31-P-0014-01A |
| 59 |
Replace rear axle breather (55) on end cover (54) |
Models 129, 140, 170, 202, 208, 210, 220 |
*BA35.31-P-1005-02A |
| |
|
Model 203 |
*BA35.31-P-1003-02B |
| 60 |
Remove rear axle differential (50) from assembly stand |
|
|
 |
Install |
|
|
| 61 |
Install rear axle differential (50). |
Model 129 |
AR35.31-P-0520C |
| |
|
Model 140 |
AR35.31-P-0520A |
| |
|
Model 170, 202, 208 |
AR35.31-P-0520D |
| |
|
Model 203, except models 203.004/204 with taxi version, code 450 Model 203.004/204 with taxi version code 450 |
AR35.31-P-0520P |
| |
|
Model 210 |
AR35.31-P-0520B |
| |
|
Model 220 |
AR35.31-P-0520I |
| 62 |
Pour oil into the rear axle differential (50) |
Model 129, 140, 170, 202, 208, 210 |
AR35.31-P-0520-03A |
| |
|
Model 129 |
*BF35.31-P-1001-01C |
| |
|
Model 140 |
*BF35.31-P-1001-01A |
| |
|
Model 170 |
*BF35.31-P-1001-01F |
| |
|
Model 202 |
*BF35.31-P-1001-01D |
| |
|
Model 208 |
*BF35.31-P-1001-01H |
| |
|
Model 210 |
*BF35.31-P-1001-01E |
| |
|
Cleaning spray, Loctite 7063 (150ml) |
*BR00.45-Z-1046-04A |
| |
|
Sealant, Omnifit 100H (50 g) |
*BR00.45-Z-1061-01A |
| |
|
Oil filler screw for rear axle differential |
*BA35.31-P-1002-02A |
| |
|
Model 203, 220 |
AR35.31-P-0520-03I |
| |
|
Model 203 |
*BF35.31-P-1001-01K |
| |
|
Model 220 |
*BF35.31-P-1001-01J |
| |
|
Cleaning spray, Loctite 7063 (150ml) |
*BR00.45-Z-1046-04A |
| |
|
Sealant, Omnifit 100H (50 g) |
*BR00.45-Z-1061-01A |
| |
|
Oil filler screw for rear axle center assembly, model 220 |
*BA35.31-P-1002-02A |
| |
|
Oil filler screw for rear axle center assembly, model 203 |
*BA35.31-P-1001-02B |
 |
Oil filler/drain screw on rear axle differential modified |
Phased in as of 19.01.04 |
BT35.31-P-0015-01A |