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Home >> Mercedes Benz >> 2003 >> S500 Base >> Repair and Diagnosis >> Suspension >> Rear Suspension >> Rear Axle-- Testing & Repair -- 215 & 220 Chassis - 2 Of 2 >> Testing & Repair >> Disassembling and assembling rear axle differential, adjusting gear set - AR35.31-P-0550A >> Attaching end cover - AR35.31-P-0550-28AA

Attaching end cover - AR35.31-P-0550-28AA

REFER TO COMPONENT MODIFICATIONS Rear axle differential end cover with non-machined sealing surface Model 170, 202.193, 208, 210, 220 with rear axle differential dia. 198 as of production period 23.5.00, model 202.194 with rear axle differential dia. 198 as of production period 23.5.00 with taxi version code 450 BT35.31-P-0014-01A
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 170 Model 202
BA35.31-P-1001-02A Bolt, end cover to rear axle differential Bolt+washer Nm - 50
Flange bolt
(TORX, internal serrations)		 Stage 1 Nm 30 30
2nd stage ∠° 45 45
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 208
BA35.31-P-1001-02A Bolt, end cover to rear axle differential Bolt+washer Nm -
Flange bolt
(TORX, internal serrations)		 Stage 1 Nm 30
2nd stage ∠° 45
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 210 Model 220
BA35.31-P-1001-02A Bolt, end cover to rear axle differential Bolt+washer Nm 50 -
Flange bolt
(TORX, internal serrations)		 Stage 1 Nm 30 30
2nd stage ∠° 45 45
TORQUE SPECIFICATION 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-1004-02B Bolt, end cover to rear axle differential Bolt+washer Nm -
Flange bolt
(TORX, multipoint socket)		 1st stage Nm 30
2nd stage ∠° 45
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 203.035/045/ 235/245/735/ 745/747, 203.061/261 up to 08/2002, Model 203.004/006/ 204/ 206/706 up to 08/2002
BA35.31-P-1004-02B Bolt, end cover to rear axle differential Bolt+washer Nm 50
Flange bolt
(TORX, multipoint socket)		 1st stage Nm 30
2nd stage ∠° 45
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 203.006/007/ 008/064/206/ 207/208/264/ 706/707/708/ 764, 203.004/204 with code 450 up to 08/2002 Model 203.0007/207/ with Code 450
BA35.31-P-1004-02B Bolt, end cover to rear axle differential Bolt+washer Nm 50
Flange bolt
(TORX, multipoint socket)		 1st stage Nm 30
2nd stage ∠° 45
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 209.365/ 465
BA35.31-P-1004-02B Bolt, end cover to rear axle differential Bolt+washer Nm -
Flange bolt
(TORX, multipoint socket)		 1st stage Nm 30
2nd stage ∠° 45
Fig 1: Identifying Sealant Gun 112 589 00 25 00
G04635053
Fig 2: Identifying Torque Wrench 001 589 66 21 00
G04635054
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1013-01A Sealant A 003 989 98 20
  1. Clean machined sealing surface (a) or non-machined sealing surface (b) at old end cover (A) or new end cover (B) as well as sealing surface at rear axle differential housing.

    IMPORTANT All sealing surfaces must be free of oil and grease.

    Shown: End cover of rear axle differential with ring gear dia. 185 mm. 

    Fig 3: Identifying Old And New End Covers
    G04635055
  2. Apply sealing compound around circumference of sealing surface (arrow).

    IMPORTANT The sealing compound must be applied only to the specified sealing surfaces (arrow) with a bead of 2.0 mm ± 0.5 mm. The sealing compound must be applied within 10 min. The silicone bead must not be spread. Only the approved sealant may be used.

    Shown: End cover of rear axle differential with ring gear dia. 185 mm. 

    Fig 4: Locating Sealing Surfaces
    G04635056

    IMPORTANT Use flange bolts.

  3. Position the end cover (54) and secure with flange bolts.

    IMPORTANT The end cover (54) must not slip.

  4. Tighten the flange bolts with SPECIAL TOOL torque wrench to stage 1 TORQUE SPECIFICATION .
  5. Mark bolt flanges relative to rear axle differential housing (a).
  6. Place mark (b) on rear axle differential offset by 45°.
  7. Tighten flange bolts with 45° tightening angle as per stage 2.

IMPORTANT The markings (a, b) should coincide The tightening angle can also be checked using a commercially available angle tester.

Fig 5: Tightening Flange Bolts With 45 Degree Tightening Angle
G04635057
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