Remove/install inside CV joint or rubber boots on rear axle shaft - AR35.30-P-0660A: Notes

MODEL 129, 140, 170, 202, 203.006 /016 /206 /216 /706, 208, 209, 210, 215, 220 up to 30.9.99

MODEL 203.004 with CODE (450) taxi version

Fig 1: Identifying CV Joint Or Rubber Boots On Rear Axle Shaft Remove/Install Components

	Remove/install
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the four pillars of the hoist and position the four support plates at the hoist mounting points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
1	Raise vehicle with lifting platform
2	Remove rear wheel
	Remove and install wheels		AP40.10-P-4050Z
3	Remove rear axle shaft (37a)	Models 129, 140, 170, 202, 203, 208, 209, 210	AR35.30-P-0620A
		Model 215, 220	AR35.30-P-0620I
	Rear axle shaft modified from solid shaft to hollow shaft	MODEL 215, 220 as of 01.10.99	BT35.30-P-0007-01I
4	Detach hose clamps (37k)	Installation: Replace hose clamps (37k), observing the width of the hose clamps.
	Rear axle shaft rubber boot and hose clamp modified	Models 129, 140, 202	BT35.30-P-0003-01A
5	Detach end cover (37h) and cup seal (37i) from inner joint ring (37c)	Installation: Replace end cover (37h).
		Installation: Attach end cover (37h) and cup seal (37i) to inner joint ring (37c).	AR35.30-P-0660-01A
		Model 129, 140, 170, 202, 208, 209, 210, 215, 220	*BF35.30-P-1001-01A
		Model 203	*BF35.30-P-1001-01D
		Sealing compound	*BR00.45-Z-1008-01A
		Sealing compound	*BR00.45-Z-1009-01A
		Sealing compound	*BR00.45-Z-1010-01A
6	Remove circlip (37g)	Installation: Replace circlip (37g).
7	Detach rubber boot (37l) with cup seal (37i)	Installation: Fit a suitable assembly sleeve on the splined profile of the rear axle shaft (37a) in order to prevent damage to the splined profile.
8	Press inner constant velocity joint off of rear axle shaft	The inner constant velocity joint consists of the inner joint ring (37c), the joint hub (37d), the balls (37e) and the ball retainer (37f).	AR35.30-P-0660-02A
	Shell halves (2 ea.) for pressing off and caulking the inner constant velocity joint.		WF58.50-P-3530-01A
		Clamping jaws	Figure
		Clamping jaws	Figure
		Drift	Figure
9	Detach rubber boot (37m)	The rubber boot (37m) of the rear axle shaft (37a) on the outer joint ring (37b) can only be replaced after disassembling the inner constant velocity joint because the outer constant velocity joint cannot be disassembled. Installation: Scrape off the grease inside the rubber boot (37m) and use it to fill the outer constant velocity joint; replace grease if necessary.
		Model 129, 140, 170, 202, 208, 209, 210, 215, 220	*BF35.30-P-1002-01A
		Model 203 Installation: To pull on the rubber boot (37m) fit a suitable assembly sleeve on the splined profile of the rear axle shaft (37a).	*BF35.30-P-1002-01D
	Checking
10	Disassemble inner constant velocity joint and check for wear and damage	The inner constant velocity joint consists of the inner joint ring (37c), the joint hub (37d), the balls (37e) and the ball retainer (37f).	AR35.30-P-0660-03A
	Rear axle shaft has been reinforced at ball retainer	Model 129	BT35.30-P-0001-01A
11	Install in the reverse order

Rear axle shaft

Number	Designation			Model 129.058/059/060/061/063/064	Model 129.066/067/068/076	Model 140.02/03/1
BF35.30-P-1001-01A	Filling capacity	Inner constant-velocity joint	g	120	150	120
BF35.30-P-1002-01A	Filling capacity	Outside constant velocity joint	g	120	120	120

Rear axle shaft

Number	Designation			Model 140.04/05/06/07	Model 170.435/444	Model 170.445/447/449/465/466
BF35.30-P-1001-01A	Filling capacity	Inner constant-velocity joint	g	100	120	100
BF35.30-P-1002-01A	Filling capacity	Outside constant velocity joint	g	100	120	100

Rear axle shaft

Number	Designation			Model 202.018/020/022/023/025/026/078/080/081/082/083/086/087/088/120/121/122/125/180/182	Model 202.024/028/029/033/085/089/093/128/133/134/188/193/194	Model 208.335/335/344/435/444/445
BF35.30-P-1001-01A	Filling capacity	Inner constant-velocity joint	g	150	100	100
BF35.30-P-1002-01A	Filling capacity	Outside constant velocity joint	g	120	100	100

Rear axle shaft

Number	Designation			Model 208.347/347/348/370/374/ 447/448/ 448/465	Model 208.474	Model 209.316 with transmission 716 Model 209.365/465
BF35.30-P-1001-01A	Filling capacity	Inner constant-velocity joint	g	120	150	120
BF35.30-P-1002-01A	Filling capacity	Outside constant velocity joint	g	120	130	120

Rear axle shaft

Number	Designation			Model 209.316 with transmission 722	Model 209.341/342/343/361	Model 209.441/442
BF35.30-P-1001-01A	Filling capacity	Inner constant-velocity joint	g	120	100	100
BF35.30-P-1002-01A	Filling capacity	Outside constant velocity joint	g	140	100	120

Rear axle shaft

Number	Designation			Model 209.372/375/376/377/472/475/476/477	Model 210.003/004/010/035/037/048/061/062/210/235/237/248/261/262/610	Model 210.006/007/015/016/017/020/025/026/045/053/055/063/065/07/08/206/215/216/217/225/226/245/263/265/27/28/606/616/617/663
BF35.30-P-1001-01A	Filling capacity	Inner constant-velocity joint	g	150	100	120
BF35.30-P-1002-01A	Filling capacity	Outside constant velocity joint	g	140	100	120

Rear axle shaft

Number	Designation			Model 215.375/376/378	Model 220.026/063/065/067/070/083/084/087/126/163/165/167/170/183/184/187	Model 220.025/028/073/075/125/128/173/175/875/878
BF35.30-P-1001-01A	Filling capacity	Inner constant-velocity joint	g	150	120	150
BF35.30-P-1002-01A	Filling capacity	Outside constant velocity joint	g	120	120	120

Rear axle shaft

Number	Designation			Model 203.004/204 with code 450, inserted axle shaft	Model 203.004/204 with code 450, screwed axle shaft	Model 203.006/206/706 with transmission 722
BF35.30-P-1001-01D	Filling capacity	Inner constant-velocity joint	g	120	120	120
BF35.30-P-1002-01D	Filling capacity	Outside constant velocity joint	g	140	120	120

Rear axle shaft

Number	Designation			Model 203.006/206/706 with screwed rear axle shaft	Model 203.006/206/706 with inserted axle shaft, except transmission 722	Model 203.008/016/20 8/216/708 with transmission 722, model 203.007/207 with transmission 722 and code 450
BF35.30-P-1001-01D	Filling capacity	Inner constant-velocity joint	g	120	120	105
BF35.30-P-1002-01D	Filling capacity	Outside constant velocity joint	g	120	140	120

Rear axle shaft

Number	Designation			Model 203.016/216 except trans. 722
BF35.30-P-1001-01D	Filling capacity	Inner constant-velocity joint	g	150
BF35.30-P-1002-01D	Filling capacity	Outside constant velocity joint	g	130

Fig 2: Identifying Clamping Jaws (116 589 11 31 00)

Fig 3: Identifying Clamping Jaws (220 589 02 31 00)

Fig 4: Identifying Drift (116 589 15 15 00)

Repair materials

Number	Designation	Order number
BR00.45-Z-1008-01A	Curil sealing compound	ElringKlinger AG Max-Eyth-Strasse 2 72581 Dettingen/Ems Germany Tel. +49 7123 724-0 Fax +49 7123 724 9006 www.elringklinger.de
BR00.45-Z-1010-01A	Sealant	A 001 989 25 20
BR00.45-Z-1009-01A	Sealant	A 001 989 89 20