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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 >> Replace radial sealing ring on connecting flange of rear axle shaft - AR35.31-P-0540I >> Notes

Replace radial sealing ring on connecting flange of rear axle shaft - AR35.31-P-0540I: Notes

Rear axle differential dia. 198 in MODEL 220.063 /065 /067 /083 /084 /087 /165 /167 /183 /184 /187 

Rear axle differential dia. 210 in MODEL 215.375 /378, 220.025 /026 /028 /070 /075 /126 /128 /170 /175 /178 

rear axle center assembly 210E 

Shown on rear axle center assembly dia. 198 mm 

Fig 1: Identifying Flange Of Rear Axle Shaft - Shown On Rear Axle Center Assembly Dia. 198 mm
G04845521
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
1 Raise vehicle    
2 Drain oil from rear axle differential   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 
    TORQUE SPECIFICATION Oil drain screw *BA35.31-P-1003-02A 
REFER TO COMPONENT MODIFICATIONS 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)   AR35.31-P-0520I 
4 Clamp rear axle differential (50) in assembly stand   AR35.31-P-0540-06B 
    SPECIAL TOOL Assembly stand Figure
    SPECIAL TOOL Supports (2 ea.) Figure
    SPECIAL TOOL Supports Figure
5 Detach extension bracket (54a) from rear axle center assembly (50) TORQUE SPECIFICATION Replace collar bolt securing extension bracket to rear axle differential (54b). *BA35.10-P-1002-02A 
6.1 Remove end cover (54) with machined sealing surface IMPORTANTInstallation:  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: ↓  
    Rear axle center assembly dia. 198 mm up to 22.05.00 AR35.31-P-0550-28A 
    Sealant *BR00.45-Z-1010-01A 
    TORQUE SPECIFICATION Bolt + washer or flange bolt *BA35.31-P-1001-02A 
    Rear axle center assembly dia. 210 mm in rear axle center assembly 210E up to 14.05.00 AR35.31-P-0550-28E 
    Sealant *BR00.45-Z-1010-01A 
    TORQUE SPECIFICATION Bolt + washer or flange bolt *BA35.31-P-1001-02A 
REFER TO COMPONENT MODIFICATIONS Rear axle differential end cover with nonmachined sealing surface   BT35.31-P-0014-01A
6.2 Remove end cover (54) with non-machined sealing surface IMPORTANTInstallation:  Fit end cover: ↓  
    Rear axle center assembly dia. 198 mm as of 23.05.00 AR35.31-P-0550-28AA 
    SPECIAL TOOL Sealant gun Fig 5
    Sealant *BR00.45-Z-1013-01A 
    TORQUE SPECIFICATION Bolt + washer or flange bolt *BA35.31-P-1001-02A 
    Rear axle center assembly dia. 210 mm in rear axle center assembly 210E as of 15.05.00 AR35.31-P-0550-28EA 
    SPECIAL TOOL Sealant gun Fig 5
    Sealant *BR00.45-Z-1013-01A 
    TORQUE SPECIFICATION Bolt + washer or flange bolt *BA35.31-P-1001-02A 
7 Detach circlip (30) IMPORTANTInstallation:  Replace circlip. AR35.31-P-0540-01A 
    SPECIAL TOOL Removal and installation tool Figure
8 Pull out connecting flange (33) NOTES Check contact surface for radial sealing ring (32) on connecting flange; in the case of galling: ↓
Replace connecting flange		  
    IMPORTANTInstallation:  Check, adjust axial play of connecting flange AR35.31-P-0540-02C 
    Axial play between connecting flange and differential housing *BE35.31-P-1001-05A 
REFER TO COMPONENT MODIFICATIONS Radial seal on side of rear axle housing and connecting flange modified As of 01.10.01 with model 220 with rear axle center assembly dia. 198 mm and with models 215, 220 with rear axle center assembly dia. 210 mm in rear axle center assembly 210E BT35.31-P-0013-01B
9.1 Press protection ring off connecting flange (33) As of 01.10.01 with model 220 with rear axle center assembly dia. 198 mm and with models 215, 220 with rear axle center assembly dia. 210 mm in rear axle center assembly 210E
IMPORTANT If a new radial sealing ring (32) is installed for the first time, a new protection ring must also be installed.
This is the only way to ensure a proper seal.		 AR35.30-P-0620-05R 
    SPECIAL TOOL Drift Figure
10 Press off radial sealing ring (32) IMPORTANT Installation: Replace radial sealing ring and coat the lip with universal hypoid transmission oil. AR35.31-P-0540-05C 
REFER TO CAPACITIES & SPECIFICATIONS Universal hypoid-gear lubricants   BB00.40-P-0235-07A
    SPECIAL TOOL Drift Figure
REFER TO COMPONENT MODIFICATIONS Radial seal on side of rear axle housing and connecting flange modified As of 01.10.01 with model 220 with rear axle center assembly dia. 198 mm and with models 215, 220 with rear axle center assembly dia. 210 mm in rear axle center assembly 210E BT35.31-P-0013-01B
11 Replace breather (55) on rear axle center assembly TORQUE SPECIFICATION *BA35.31-P-1005-02A 
12 Install in the reverse order    
13 Check oil level in rear axle differential and correct if necessary IMPORTANT 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-0520-03I 
    FLUID SPECIFICATION Filling capacity of rear axle differential *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 
    TORQUE SPECIFICATION Oil filler screw for rear axle differential *BA35.31-P-1002-02A 
REFER TO COMPONENT MODIFICATIONS Oil filler/drain screw on rear axle differential modified Phased in as of 19.01.04 BT35.31-P-0015-01A
TEST VALUES FOR CONNECTING FLANGE/DIFFERENTIAL HOUSING

Number Designation Model 215 Model 220
BE35.31-P-1001-05A Axial play between connecting flange and differential housing mm 0.03-0.3 0.03-0.3
TORQUE SPECIFICATION EXTENSION BRACKET FOR REAR AXLE CENTER ASSEMBLY

Number Designation Model 215.374/ 376/379 Models 220.025/026/ 028/ 063/065/067/ 070/073/075/ 083/084/087/ 125/126/128/ 165/167/170/ 173/175/178/ 183/184/187
BA35.10-P-1002-02A Bolt, extension bracket to rear axle center assembly Yellow Nm 80 80
silver or blue Nm 70 70
TORQUE SPECIFICATION REAR AXLE CENTER ASSEMBLY HOUSING

Number Designation Model 215 Model 220
BA35.31-P-1001-02A Bolt, end cover to rear axle differential 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 for rear axle differential Nm 50 50
BA35.31-P-1005-02A Breather, rear axle center assembly Nm 30 30
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 215.373/375/ 378 Model 220.063/065/ 067/083/084/ 087/163/165/ 167/183/184/187 Model 220.025/026/ 028/070/073/ 075/125/126/ 128/170/173/ 178 Model 220.175 without special protection version code 979
BF35.31-P-1001-01J Filling capacity Rear axle differential Liters 1.6 1.1 1.6
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A BB00.40-P-0235-07A BB00.40-P-0235-07A
Fig 2: Identifying Assembly Stand (129 589 00 31 00)
G04845522
Fig 3: Identifying Supports (2 ea.) (140 589 40 63 00)
G04845523
Fig 4: Identifying Supports (220 589 01 63 00)
G04845524
Fig 5: Identifying Sealant Gun (112 589 00 25 00)
G04845525
Fig 6: Identifying Removal And Installation Tool (116 589 01 62 00)
G04845526
Fig 7: Identifying Drift (140 589 10 15 00)
G04845527
Fig 8: Identifying Drift (140 589 16 15 00)
G04845528
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1061-01A Sealant, Omnifit 100H (50 g) A 002 989 23 71
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
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