Replace radial seal ring on connecting flange of rear axle shaft - AR35.31-P-0540D

Rear axle center assembly dia. 168 in MODEL 170.435, 202.018 /078 /120 /121 /125 /182

Rear axle center assembly dia. 185 in MODEL 170.444 /445 /447 /449, 202.018 /020 /022 /023 /024 /025 /026 /028 /029 /078 /080 /081 /082 /083 /086 /087 /088 /089 /120 /121 /122 /125 /128 /182 /188, 208.335 /344 /345 /347 /348 /435 /444 /445 /447 /448

Rear axle center assembly dia. 185 in MODEL 202.134 /194 except CODE (450) Taxi version

Rear axle center assembly dia. 185 in MODEL 202.085 with TRANSMISSION 722

Fig 1: Identifying Radial Seal Ring On Connecting Flange Of Rear Axle Shaft Components

	Remove/Install
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
1	Raise vehicle.
2	Drain oil from rear axle center assembly		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 plug	*BA35.31-P-1003-02A
	Oil filler and drain screw on rear axle center assembly modified	as of 19.01.04	BT35.31-P-0015-01A
3	Remove rear axle center assembly (50)		AR35.31-P-0520D
4	Clamp rear axle center assembly (50) in assembly stand		AR35.31-P-0540-06B
		Assembly stand	Figure
		Assembly stand	Figure
5.1	Remove end cover (54) with machined sealing surface	Installation: If a replacement part end cover is fitted it is absolutely essential to observe whether the sealing surface is machined or not. Use suitable sealant. Fit end cover: ↓
		168 mm dia. rear axle center assembly in models 170, 202 up to 07.05.00	AR35.31-P-0550-28B
		Sealant	*BR00.45-Z-1010-01A
		Bolt + washer or flange bolt	*BA35.31-P-1001-02A
		185 mm dia. rear axle center assembly in model 170, 202, 208 up to 07.05.00	AR35.31-P-0550-28C
		Sealant	*BR00.45-Z-1010-01A
		Bolt + washer or flange bolt	*BA35.31-P-1001-02A
	Rear axle center assembly end cover with nonmachined sealing surface		BT35.31-P-0014-01A
5.2	Detach end cover (54) with non-machined sealing surface	Installation: Fit end cover: ↓
		168 mm dia. rear axle center assembly in models 170, 202 as of 08.05.00	AR35.31-P-0550-28BA
		Sealant gun	Figure
		Sealant	*BR00.45-Z-1013-01A
		Bolt + washer or flange bolt	*BA35.31-P-1001-02A
		185 mm dia. rear axle center assembly in models 170, 202, 208 as of 08.05.00	AR35.31-P-0550-28CA
		Sealant gun	Figure
		Sealant	*BR00.45-Z-1013-01A
		Bolt + washer or flange bolt	*BA35.31-P-1001-02A
6	Detach circlip (30)	Installation: Replace circlip.	AR35.31-P-0540-01A
		Removal and installation tool	Figure
7	Remove connecting flange (33, 33a, 33b)	Check contact surface for radial sealing ring on connecting flange; if it is severely galled: ↓ Replace connecting flange. Installation: Check and adjust axial play of connecting flange: ↓ No axial play adjustment is required on vehicles with rear axle with automatic locking differential (ASD) code 211a.
		Model 170.435, 202.180 Model 202.018/078/120/121/122/125/182, except Taxi version	AR35.31-P-0540-02D
		Axial play between connecting flange and differential housing	*BE35.31-P-1001-05A
		Model 170.444/445/447/449, Model 202.020/022/023/024/025/026/028/029/080/081/082/083/086/087/088/089/128/188, Standard, Model 202.085 with 5-speed automatic transmission, Model 202.018/078/120/121/122/ 125/182 standard with taxi version code 450, Model 202.134/194 except taxi version, model 208.335/344/345/347/348/435/444/ 445/447/448	AR35.31-P-0540-02E
		Axial play between connecting flange and differential housing	*BE35.31-P-1001-05A
	Radial seal on side of rear axle housing and connecting flange modified	As of 01.04.98: on model 170.445/447, Model 202.020/022/023/024/025/026/028/029/080/082/083/085/086/089/128/188, Standard, model 202.018/078/120/121/122/125/182 standard with taxi version code 450, Model 202.134/194 except taxi version, model 208.335/345/347/435/445/447	BT35.31-P-0013-01A
8	Detach grooved ball bearing (33c)	Model 202 with rear axle with automatic locking differential (ASD) code 211a	AR35.31-P-0540-04A
		Tensioning clamp	Fig 6
		Puller	Figure
9	Press off radial seal ring (32, 32a, 70j)	Installation: Replace radial sealing ring and coat the lip with universal hypoid transmission oil.
	Universal hypoid gear oil (SAE 85 W-90)		BB00.40-P-0235-07A
		Model 170.435, 202.180 Model 202.018/120/121/125 except taxi version, except ASD automatic locking differential Model 202.078/122/182 except taxi version	AR35.31-P-0540-05E
		Drift	Figure
		Model 202.018/020/022/023/024/025/026/028/029/078/08/120/121/122/125/128/182/188 with rear axle with automatic locking differential (ASD) code 211a	AR35.31-P-0540-05G
		Extractor tool	Fig 9
		Drift	Fig 10
		Model 202.028 up to 05/94 with acceleration slip regulation (ASR) code 471a	AR35.31-P-0540-05H
		Drift	Fig 11
		Model 170.444/445/447/449, Model 202.020/022/023/024/025/026/028/029/080/081/082/083/085/086/087/088/089/128/188, Standard, Model 202.085 with 5-speed automatic transmission, Model 202.018/078/120/121/122/ 125/182 standard with taxi version code 450, model 202.028 as of 06/94 with acceleration slip regulation (ASR) code 471a, Model 202.134/194 except taxi version, Model 208.335/344/345/347/348/435/444/ 445/447/448	AR35.31-P-0540-05F
		Drift	Figure
	Radial seal on side of rear axle housing and connecting flange modified	As of 01.04.98: on model 170.445/447, Model 202.020/022/023/024/025/026/028/029/080/082/083/085/086/089/128/188, Standard, model 202.018/078/120/121/122/125/182 standard with taxi version code 450, Model 202.134/194 except taxi version, model 208.335/345/347/435/445/447	BT35.31-P-0013-01A
10	Replace breather of rear axle center assembly (55)		*BA35.31-P-1005-02A
11	Install in the reverse order
12	Check oil level in rear axle center assembly 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-0520-03A
		Model 170 rear axle center assembly filling capacity	*BF35.31-P-1001-01F
		Model 202 rear axle center assembly filling capacity	*BF35.31-P-1001-01D
		Model 208 rear axle center assembly filling capacity	*BF35.31-P-1001-01H
		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	*BA35.31-P-1002-02A
	Oil filler and drain screw on rear axle center assembly modified	as of 19.01.04	BT35.31-P-0015-01A

Test values for connecting flange/differential housing

Number	Designation		Model 170	Model 202	Model 208
BE35.31-P-1001-05A	Axial play between connecting flange and differential housing	mm	0,03-0,3	0,03-0,3	0,03-0,3

Rear axle center assembly housing

Number	Designation				Model 170	Model 202
BA35.31-P-1001-02A	Bolt, end cover to rear axle center assembly	Bolt+washer		Nm	-	50
		Flange bolt (TORX, internal serrations)	Stage 1	Nm	30	30
		Flange bolt (TORX, internal serrations)	2nd stage	∠ °	45	45
BA35.31-P-1002-02A	Oil filler plug, rear axle center assembly			Nm	50	50
BA35.31-P-1003-02A	Oil drain screw for rear axle center assembly			Nm	50	50
BA35.31-P-1005-02A	Breather, rear axle center assembly			Nm	25	25

Rear axle center assembly housing

Number	Designation				Model 208
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
		Flange bolt (TORX, internal serrations)	2nd stage	∠ °	45
BA35.31-P-1002-02A	Oil filler plug, rear axle center assembly			Nm	50
BA35.31-P-1003-02A	Oil drain screw for rear axle center assembly			Nm	50
BA35.31-P-1005-02A	Breather, rear axle center assembly			Nm	25

Rear final-drive unit

Number	Designation			Model 202.018/020/ 022/120/121/125, with (Code 211) ASD	Model 202.018/078/ 120/121/122/ 125/182 except (Code 450) Taxi version, Model 202.018/120/ 121/125, without (Code 211) ASD, Model Series 202.180
BF35.31-P-1001-01D	Filling capacity	Rear axle center assembly	Liters	1.1	0.7
		Specifications for Operating Fluids	Sheet	-	BB00.40-P-0235-07A
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-00A	BB00.40-P-0235-07A

Rear final-drive unit

Number	Designation			Model 202.018/078/ 120/121/122/ 125/182, without (Code 211) ASD, with (Code 450) taxi equipment	Model 202.020/022/ 023/024/025/ 026/028/029/ 080/081/082/ 083/086/087/ 088/089/128/ 188 without (code 211) ASD, model 202.085 with automatic 5-speed transmission, model 202.134/194 except(code 450) taxi version
BF35.31-P-1001-01D	Filling capacity	Rear axle center assembly	Liters	1.1	1.1
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-00A	BB00.40-P-0235-00A
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	BB00.40-P-0235-07A

Rear final-drive unit

Number	Designation			Model 170.435	Models 170.444/ 444/445/ 449
BF35.31-P-1001-01F	Filling capacity	Rear axle center assembly	Liters	0.7	1.1
BF35.31-P-1001-01F	Filling capacity	Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	BB00.40-P-0235-07A

Rear final-drive unit

Number	Designation			Model 208.335/344/345/ 347/348/435/44 4/445/447/448
BF35.31-P-1001-01H	Filling capacity	Rear axle center assembly	Liters	1.1
BF35.31-P-1001-01H	Filling capacity	Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A

Fig 2: Identifying Assembly Stand (201 589 03 31 00)

Fig 3: Identifying Assembly Stand (129 589 00 31 00)

Fig 4: Identifying Sealant Gun (112 589 00 25 00)

Fig 5: Identifying Removal And Installation Tool (116 589 01 62 00)

Fig 6: Identifying Collet Chuck (140 589 00 34 00)

Fig 7: Identifying Puller (001 589 50 33 00)

Fig 8: Identifying Drift (201 589 03 15 00)

Fig 9: Identifying Extraction Tool (129 589 02 33 00)

Fig 10: Identifying Drift (124 589 01 15 00)

Fig 11: Identifying Drift (126 589 04 15 00)

Fig 12: Identifying Drift (126 589 00 15 00)

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-1010-01A	Sealant	A 001 989 25 20
BR00.45-Z-1046-04A	Cleaning spray, Loctite 7063 (150ml)	A 001 986 71 71 10