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Home >> Mercedes Benz >> 2004 >> C32 >> Repair and Diagnosis >> Suspension >> Rear Suspension >> Rear Axle -- Testing & Repair -- 203 Chassis - 2 Of 2 >> Testing & Repair >> Disassembling and assembling rear axle differential, adjusting gear set - AR35.31-P-0550C

Disassembling and assembling rear axle differential, adjusting gear set - AR35.31-P-0550C

Rear axle differential dia. 185 in model 124.003 /004 /007 /019 /022 /023 /026 /027 /030 /040 /042 /043 /050 /060 /062 /079 /082 /083 /090, 124.104 /107 as of 1.5.94, 124.127 /128 /129 /130 /131 /133 /188 /190 /191 /193 /226 /230 /290 /330 /333 /393, 129.060, 170.444 /445 /447 /449, 201.028 /029 /035 /036 /128, 202.020 /022 /023 /024 /025 /026 /028 /029 /080 /081 /082 /083 /086 /087 /088 /089 /128 /188, 203.035 /045, 203.061 up to 31.8.02, 203.235 /245, 203.261 up to 31.8.02, 203.735 /745 /747, 208.335 /344 /345 /347 /348 /435 /444 /445 /447 /448, 210.010 /020 /035 /037 /048 /061 /062 /210 /235 /237 /248 /261 /262 /610 

Rear axle differential dia. 185 in model 124.020 /021 /080 /081 /120 /125 /126 /180 /185 /186, 201.018 /023 /024 /122 /126 as of 1.11.88, 202.018 /078 /120 /121 /122 /125 /182, 210.003 /004 with CODE (450) taxi version 

Rear axle differential dia. 185 in model 124.186 as of 1.3.94, 202.134 /194, 203.004 /204 up to 31.8.02, 210.007 except CODE (450) Taxi version 

Rear axle differential dia. 185 in model 202.018 /120 /121 /125 with CODE (211) rear axle with automatic locking differential (ASD) 

Rear axle differential dia. 185 in model 202.085 with TRANSMISSION 722 

Fig 1: Exploded View Of Rear Axle Differential - Dia. 185
G04635162
REMOVING Remove     
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 below the hoist 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) Model 124, 129, 170, 201, 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 
    TORQUE SPECIFICATION Oil drain screw *BA35.31-P-1003-02A 
    Model 203 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-1002-02B 
REFER TO COMPONENT MODIFICATIONS Oil filler and 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 124, 201 ra35001240520x
    Model 129 AR35.31-P-0520C
    Model 170, 202, 208 AR35.31-P-0520D
    Model 203 except model 203.045
Model 203.045.		 AR35.31-P-0520P
    Model 210 AR35.31-P-0520B
REFER TO COMPONENT MODIFICATIONS Tapped hole for rpm sensor relocated at rear axle housing Model 124, 129, 201 BT35.31-P-0004-01A
REFER TO BASIC KNOWLEDGE Features, installation survey for rear axle differentials Model 124, 129, 170, 201, 202, 208, 210 GF35.31-P-1000-01C
REFER TO BASIC KNOWLEDGE Rear axle differential complete, technical data Model 203.004/035/ 045/061 GF35.31-P-0777A
DISASSEMBLING Disassemble     
4 Clamp rear axle differential (50) SPECIAL TOOL in assembly stand. SPECIAL TOOL AR35.31-P-0540-06B
5 Remove end cover (54)    
REFER TO COMPONENT MODIFICATIONS Rear axle differential end cover with non-machined sealing surface Model 170, 202, 208, 210 as of 08.05.00 BT35.31-P-0014-01A
6.1 Pull circlips (30) off both connecting flanges (33 or 33a, 33b). SPECIAL TOOL Except model 203 AR35.31-P-0540-01A
7.1 Pull out connecting flanges (33 or 33a, 33b). SPECIAL TOOL Except model 203  
REFER TO COMPONENT MODIFICATIONS Radial seal on side of rear axle housing and connecting flange modified As of 01.04.98, vehicles without ASD/ASR BT35.31-P-0013-01A
8 Press off left and right radial sealing rings (32, 32a, 70j). SPECIAL TOOL Vehicles with rear axle with automatic locking differential (ASD) code 211a AR35.31-P-0540-05G
    Vehicles with acceleration slip regulation (ASR) code 471a AR35.31-P-0540-05H
    Vehicles without ASD/ASR AR35.31-P-0540-05F
REFER TO COMPONENT MODIFICATIONS Radial seal on side of rear axle housing and connecting flange modified As of 01.04.98, vehicles without ASD/ASR BT35.31-P-0013-01A
9.1 Remove hydraulic line (70l). Vehicles with rear axle with automatic locking differential (ASD) code 211a AR35.41-P-0545-01C 
REFER TO COMPONENT MODIFICATIONS Routing of hydraulic line and ASD ring cylinder modified As of 07/89 BT35.41-P-0002-01A
10.1 Remove ring cylinder (70). Vehicles with automatic locking differential (ASD) code 211a AR35.41-P-0545-02C 
11.1 Remove oil baffle plate (71). Vehicles with automatic locking differential (ASD) code 211a  
12 Remove right circlip (29) from rear axle housing using spreader. COMMERCIALLY AVAILABLE TOOLSIMPORTANT Mark circlip (29). AR35.31-P-0550-36C 
13 Remove left circlip (29) from rear axle housing using spreader. COMMERCIALLY AVAILABLE TOOLSIMPORTANT Mark circlip (29). *WH58.30-Z-1009-02A 
14 Remove both tapered roller bearing outer races (11a) out of rear axle housing SPECIAL TOOLIMPORTANT Mark tapered roller bearing outer races (11a) AR35.31-P-0550-02C 
15 Take differential (13) out of rear axle housing   AR35.31-P-0550-03B 
16 Detach both tapered roller bearing inner races (11b) from differential (13) SPECIAL TOOLIMPORTANT Mark tapered roller bearing inner races (11b). AR35.31-P-0550-04C 
17 Loosen and remove retaining bolts (13a) from crown wheel (47a) IMPORTANT Mark position of ring gear (47a) in relation to differential (13).  
18 Carefully press off crown wheel (47a) from differential (13)    
19 Loosen and remove twelve-point collar nut (40) from joint flange (41). SPECIAL TOOL AR35.31-P-0550-35C 
20 Detach joint flange (41). SPECIAL TOOLIMPORTANT If necessary, mark joint flange with respect to drive pinion. AR35.31-P-0550-06B 
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified as of 01.04.98 BT35.31-P-0012-01A
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified as of 15.01.02 BT35.31-P-0012-01B
21 Push drive pinion (47) out of rear axle housing SPECIAL TOOL AR35.31-P-0550-07A 
22 Press radial sealing ring (42) out of the rear axle housing using a suitable screwdriver.   AR35.31-P-0550-08B 
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified as of 01.04.98 BT35.31-P-0012-01A
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified as of 15.01.02 BT35.31-P-0012-01B
23 Remove tapered roller bearing inner race (43d) with thrust washer (43a).    
REFER TO COMPONENT MODIFICATIONS Integrated thrust washer on tapered roller bearing inner race As of 03/94 BT35.31-P-9402-01A
24 Remove tapered roller bearing outer races (46b, 43e) and shim (45) from rear axle housing. SPECIAL TOOL AR35.31-P-0550-09C 
25 Remove spacer sleeve (44) with thrust plates (48) from drive pinion (47)    
26.1 Pull ABS gear (49) off drive pinion (47). Vehicles with antilock brake system (ABS) code 470a, except vehicles with ETS, ASR, ESP AR35.31-P-0550-30B 
27 Pull tapered roller bearing inner race (46a) from drive pinion (47) SPECIAL TOOL AR35.31-P-0550-10C 
INSPECT Check     
28 Inspect all parts to determine whether they can be reused, replace if necessary IMPORTANT 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 with new flanges.  
29.1 Check drive pinion (47) and ring gear (47a) for match-up number Only lapped gear sets up to approx. 06/95 have a match-up number.
IMPORTANT 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 
REFER TO COMPONENT MODIFICATIONS Ground ring gear and pinions Phased in as of 06/95 BT35.31-P-0011-01B
REFER TO COMPONENT MODIFICATIONS Ground ring gear and pinions Model 201.028/029 USA ONLYJAPAN ONLY BT35.31-P-0011-01A
ASSEMBLING Assembly, adjusting ring gear and pinion     
30 Press tapered roller bearing inner race (46a) onto drive pinion (47)   AR35.31-P-0550-12C 
REFER TO SHOP-MADE TOOLS Press-on sleeve for tapered roller bearing inner race   WF58.50-P-3531-03B
31.1 Press ABS gear (49) onto drive pinion (47). Vehicles with antilock brake system (ABS) code 470a, except vehicles with ETS, ASR, ESP AR35.31-P-0550-31B
REFER TO SHOP-MADE TOOLS Press-on sleeve for ABS gear   WF58.50-P-3531-04B
    Number of teeth on ABS gear: ↓  
REFER TO BASIC KNOWLEDGE   Features, installation survey for rear axle differentials GF35.31-P-1000-01C
32 Calculate shim (45) and installing in rear axle housing SPECIAL TOOLIMPORTANT Use data sheet: ↓
Data sheet, Adjusting rear axle gear set: Order No. B20.800.98.113.00C		 AR35.31-P-0550-13C 
33 Pull tapered roller bearing outer races (43e, 46b) into rear axle housing SPECIAL TOOL AR35.31-P-0550-14C 
34 Install spacer sleeve (44) on drive pinion (47) with double-sided thrust plates (48) IMPORTANT Always replace spacer sleeve (44) and thrust plates (48). AR35.31-P-0550-26B 
35 Insert drive pinion (47) into rear axle housing. SPECIAL TOOLIMPORTANT Support drive pinion (47) with removal and installation tool. AR35.31-P-0550-15B 
36.1 Clip pressure plate (43a) onto tapered roller bearing inner race (43d). Rear axle differentials up to 02/94 AR35.31-P-0550-37C
REFER TO COMPONENT MODIFICATIONS Integrated thrust washer on tapered roller bearing inner race   BT35.31-P-9402-01A
37 Install tapered roller bearing inner race (43d) on drive pinion (47) and press in together with radial sealing ring (42). SPECIAL TOOLIMPORTANT Replace radial sealing ring (42) and coat the lip with universal hypoid gear oil. AR35.31-P-0550-16C 
REFER TO CAPACITIES & SPECIFICATIONS Universal hypoid-gear lubricants   BB00.40-P-0235-07A
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified as of 01.04.98 BT35.31-P-0012-01A
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified as of 15.01.02 BT35.31-P-0012-01B
38 Slide joint flange (41) onto drive pinion (47) IMPORTANT Possibly observe applied marking. Coat contact face for radial sealing ring with universal hypoid gear oil.  
REFER TO CAPACITIES & SPECIFICATIONS Universal hypoid-gear lubricants   BB00.40-P-0235-07A
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified as of 01.04.98 BT35.31-P-0012-01A
REFER TO COMPONENT MODIFICATIONS Radial sealing ring and joint flange on drive pinion modified as of 15.01.02 BT35.31-P-0012-01B
REFER TO COMPONENT MODIFICATIONS Imbalance on drive pinion joint flange reduced Model 124, 129, 201 BT35.31-P-0007-01A
39 Screw on twelve-point collar nut (40). IMPORTANT Install new twelve-point collar nut (40).  
    SPECIAL TOOL Socket Fig 37
40 Adjusting friction torque of drive pinion bearing SPECIAL TOOL AR35.31-P-0550-17C 
41 Check adjustment dimension for drive pinion (47) SPECIAL TOOL AR35.31-P-0550-18C 
42 Secure twelve-point collar nut (40) on joint flange (41).   AR35.31-P-0530-01B
REFER TO SHOP-MADE TOOLS Chisel for securing collar nut on joint flange   WF58.50-P-3531-01A
43.1 Dismantling and assembling differential (13) SPECIAL TOOL Vehicles without ASD AR35.31-P-0560A 
43.2 Disassemble/assemble ASD differential (13). SPECIAL TOOL Vehicles with rear axle with automatic locking differential (ASD) code 211a AR35.41-P-0560C
44 Mount ring gear (47a) onto differential (13) SPECIAL TOOLIMPORTANT Observe marking applied to ring gear (47a) and differential (13). AR35.31-P-0550-19A 
REFER TO COMPONENT MODIFICATIONS Tightening torque of ring gear bolts reduced Model 124, 129, 201 as of 01.02.87 BT35.31-P-0005-01A
45 Press tapered roller bearing inner races (11b) onto differential (13) SPECIAL TOOL AR35.31-P-0550-20C 
46 Install differential (13) in rear axle housing IMPORTANT Fix differential (13) with drifts. AR35.31-P-0550-03B 
47 Insert left tapered roller bearing outer race (11a) into rear axle housing SPECIAL TOOL AR35.31-P-0550-38C 
48 Insert left circlip (29) COMMERCIALLY AVAILABLE TOOLSIMPORTANT Install the circlip (29) removed and marked previously in order to achieve a basic pretension of the rear axle housing. AR35.31-P-0550-27C 
49 SPECIAL TOOL Remove right drift from differential (13).    
50 Install right tapered roller bearing outer race (11a) in rear axle housing. SPECIAL TOOL Drift Fig 38
51 Pretension (spread) rear axle housing using SPECIAL TOOL spreader. SPECIAL TOOLIMPORTANT Ensure that the dial indicator with measuring bracket remains in position "0". AR35.31-P-0550-23C 
52 Insert right circlip (29) COMMERCIALLY AVAILABLE TOOLSIMPORTANT Install the circlip (29) removed and marked previously in order to achieve a basic pretension of the rear axle housing. AR35.31-P-0550-22C 
53 Release rear axle housing    
54 Measure expanded dimension of rear axle housing SPECIAL TOOL AR35.31-P-0550-24C 
55 SPECIAL TOOL Remove spreader from rear axle housing    
56 Measure gear backlash between drive pinion (47) and ring gear (47a), correct if necessary. SPECIAL TOOLNOTES The adjustment of the tapered roller bearing and the gear set is OK when the spread dimension (expansion) of the rear axle housing 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-0550-25C 
57 Check that circlip (29) is correctly seated. SPECIAL TOOL AR35.31-P-0550-32C 
58.1 Install oil baffle plate (71). Vehicles with rear axle with automatic locking differential (ASD) code 211a
IMPORTANT Ensure correct seating.		 AR35.41-P-0545-03C 
59.1 Attach ring cylinder (70). Vehicles with rear axle with automatic locking differential (ASD) code 211a
IMPORTANT Coat ring cylinder at circumference of O-ring with hydraulic fluid.		 AR35.41-P-0545-02C 
REFER TO CAPACITIES & SPECIFICATIONS Hydraulic oils (Specification 343.0)   BB00.40-P-0343-00A
60.1 Attach hydraulic line (70l). Vehicles with rear axle with automatic locking differential (ASD) code 211a AR35.41-P-0545-01C 
REFER TO COMPONENT MODIFICATIONS Routing of hydraulic line and ASD ring cylinder modified   BT35.41-P-0002-01A
61 Press radial sealing rings (32 or 32a, 70j) into rear axle housing. SPECIAL TOOLIMPORTANT Install new radial sealing ring and coat lip with universal hypoid gear oil.  
REFER TO CAPACITIES & SPECIFICATIONS Universal hypoid-gear lubricants   BB00.40-P-0235-07A
    Vehicles with rear axle with automatic locking differential (ASD) code 211a AR35.31-P-0540-05G
    Vehicles with acceleration slip regulation (ASR) code 471a AR35.31-P-0540-05H
    Vehicles without ASD/ASR AR35.31-P-0540-05F
REFER TO COMPONENT MODIFICATIONS Radial seal on side of rear axle housing and connecting flange modified As of 01.04.98, vehicles without ASD/ASR BT35.31-P-0013-01A
62.1 Slide spacer rings (31b) onto connecting flanges (33 or 33a). Except model 203 and vehicles without ASD  
63.1 Install connecting flanges (33 or 33a, 33b) in differential (13). Except model 203  
REFER TO COMPONENT MODIFICATIONS Connecting flange with centering Model 124, 129, 201 BT35.31-P-0009-01A
REFER TO COMPONENT MODIFICATIONS Radial seal on side of rear axle housing and connecting flange modified As of 01.04.98, vehicles without ASD/ASR BT35.31-P-0013-01A
64.1 Fit circlips (30) onto connecting flanges. Except model 203
IMPORTANT Install new circlip (30).		 AR35.31-P-0540-01A
65.1 Check and adjust axial play of connecting flange Except model 203 and vehicles without ASD
IMPORTANT Adjustment of the axial play is not required for vehicles with rear axle with automatic locking differential (ASD) code 211a		 AR35.31-P-0540-02E
66 Attach end cover (54) IMPORTANT If a replacement part end cover is mounted, it is essential to observe whether the sealing surface is machined or unmachined. Use suitable sealant.  
    End cover with machined sealing surface in model 124, 129, 201 and in model 170, 202, 208, 210 up to 07.05.00 AR35.31-P-0550-28C
    End cover with unmachined sealing surface in model 203 and model 170, 202, 208, 210 as of 08.05.00 AR35.31-P-0550-28CA 
REFER TO COMPONENT MODIFICATIONS End cover with unmachined sealing surface Vehicles as of 08.05.00 BT35.31-P-0014-01A
67 Replace rear axle breather (55) on end cover (54) TORQUE SPECIFICATION Model 124, 129, 170, 201, 202, 208, 210 *BA35.31-P-1005-02A 
    TORQUE SPECIFICATION Model 203 *BA35.31-P-1003-02B 
68 Remove rear axle differential (50) from SPECIAL TOOL assembly stand    
INSTALLING Install     
69 Install rear axle differential (50). Model 124, 201 ra35001240520x
    Model 129 AR35.31-P-0520C
    Model 170, 202, 208 AR35.31-P-0520D
    Model 203 except model 203.045
Model 203.045.		 AR35.31-P-0520P
    Model 210 AR35.31-P-0520B
70 Pour oil into the rear axle differential (50) Model 129, 170, 202, 208, 210 AR35.31-P-0520-03A
    FLUID SPECIFICATION Model 129 *BF35.31-P-1001-01C 
    FLUID SPECIFICATION Model 170 *BF35.31-P-1001-01F 
    FLUID SPECIFICATION Model 202 *BF35.31-P-1001-01D 
    FLUID SPECIFICATION Model 208 *BF35.31-P-1001-01H 
    FLUID SPECIFICATION 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 
    TORQUE SPECIFICATION Oil filler screw for rear axle differential *BA35.31-P-1002-02A 
    Model 124, 201 AR35.31-P-0520-03AA
    FLUID SPECIFICATION Model 124 *BF35.31-P-1001-01B 
    FLUID SPECIFICATION Model 201 *BF35.31-P-1001-01G 
    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 
    Model 203 AR35.31-P-0520-03I
    Cleaning spray, Loctite 7063 (150ml) *BR00.45-Z-1046-04A 
    Sealant, Omnifit 100H (50 g) *BR00.45-Z-1061-01A 
    FLUID SPECIFICATION *BF35.31-P-1001-01K 
    TORQUE SPECIFICATION Oil filler screw, rear axle differential *BA35.31-P-1001-02B 
REFER TO COMPONENT MODIFICATIONS Oil filler and drain screw on rear axle differential modified Phased in as of 19.01.04 BT35.31-P-0015-01A
71.1 Bleed ASD hydraulic system Vehicles with rear axle with automatic locking differential (ASD) code 211a  
    Model 124, 201 ra35001240519x
    Model 129, 202 AR35.41-P-0519C
TEST VALUES FOR FRICTION TORQUE OF REAR AXLE DIFFERENTIAL

Number Designation Model 124.003/004/007/ 019/022/023/026/027/ 030/040/042/043/050/ 060/062/079/082/083/ 090 Model 124.104/107 as of 01.05.94 Model 124.127/128/129/ 130/131/133 Model 124.186 as of 01.03.94, except (code 450) taxi version Model 124.188/190/191/ 193/226/230/290/330/333/393 Model 124.020/021/080/ 081/120/125/126/180/ 185/186, with (code 450) taxi version as of 01.11.88 Model 129.060
BE35.31-P-1001-02C Friction torque of drive pinion bearing (new tapered roller bearings) Ncm 125-150 125-150 125-150
TEST VALUES FOR FRICTION TORQUE OF REAR AXLE DIFFERENTIAL

Number Designation Model 170.444/445/ 447/449 Model 201.018/023/024/122/126, with (code 450) taxi version as of 01.11.88 Model 201.028/ 029/035/ 036/128
BE35.31-P-1001-02C Friction torque of drive pinion bearing (new tapered roller bearings) Ncm 125-150 125-150 125-150
TEST VALUES FOR FRICTION TORQUE OF REAR AXLE DIFFERENTIAL

Number Designation Model 202.018/078/120/ 121/122/125/182 with (code 450) taxi version, Model 202.018/020/022/ 120/121/125 with ASD (code 211) Model 202.020/022/023/ 024/025/026/028/029/ 080/081/082/083/086/ 087/088/089/128/188 Model 202.085 with automatic 5-speed transmission, model 202.134/194, except (code 450)
BE35.31-P-1001-02C Friction torque of drive pinion bearing (new tapered roller bearings) Ncm 125-150 125-150
TEST VALUES FOR FRICTION TORQUE OF REAR AXLE DIFFERENTIAL

Number Designation Model 203.035/045/061 /235/245/261/73 5/745/747, Model 203.004/204 except code 450 Model 208.335/344/345/ 347/348/435/444 /445/447/448 Model 210.010/ 020/035/037/04 8/061/062/210/ 235/237/248/26 1/262/610
BE35.31-P-1001-02C Friction torque of drive pinion bearing (new tapered roller bearings) Ncm 125-150 125-150 125-150
TEST VALUES FOR FRICTION TORQUE OF REAR AXLE DIFFERENTIAL

Number Designation Model 210.003/004 with (Code 450) 210.007 except code 450
BE35.31-P-1001-02C Friction torque of drive pinion bearing (new tapered roller bearings) Ncm 125-150
TEST VALUES FOR REAR AXLE DIFFERENTIAL

Number Designation Model 124 Model 129 Model 170
BE35.31-P-1001-03A Permissible deviation from the specified adjustment dimension on the end face of the drive pinion mm -0.02/+0.01 -0.02/+0.01 -0.02/+0.01
BE35.31-P-1002-03A Gear backlash between crown wheel and pinion mm 0.08-0.14 0.08-0.14 0.08-0.14
BE35.31-P-1003-03A Crown wheel heating temperature for installation °C 75-85 75-85 75-85
TEST VALUES FOR REAR AXLE DIFFERENTIAL

Number Designation Model 201 Model 202 Model 203
BE35.31-P-1001-03A Permissible deviation from the specified adjustment dimension on the end face of the drive pinion mm -0.02/+0.01 -0.02/+0.01 -0.02/+0.01
BE35.31-P-1002-03A Gear backlash between crown wheel and pinion mm 0.08-0.14 0.08-0.14 0.10-0.16
BE35.31-P-1003-03A Crown wheel heating temperature for installation °C 75-85 75-85 75-85
TEST VALUES FOR REAR AXLE DIFFERENTIAL

Number Designation Model 208 Model 210
BE35.31-P-1001-03A Permissible deviation from the specified adjustment dimension on the end face of the drive pinion mm -0.02/+0.01 -0.02/+0.01
BE35.31-P-1002-03A Gear backlash between crown wheel and pinion mm 0.08-0.14 0.08-0.14
BE35.31-P-1003-03A Crown wheel heating temperature for installation °C 75-85 75-85
TEST VALUES FOR REAR AXLE HOUSING EXPANSION

Number Designation Model 124.003/004/007/019/ 022/023/026/027/030/040/ 042/043/050/060/062/079/ 082/083/090, Model 124.104/107 as of 01.05.94 Model 124.127/128/129/130/ 131/133, model 124.186 as of 01.03.94, except (code 450) Model 124.188/190/191/193/ 226/230/290/330/333/393 Model 124.020/021/080/ 081/120/125/126/180/ 185/186, with (code 450) as of 01.11.88
BE35.31-P-1001-04C Rear axle housing expansion (spread dimension) for circlip removal mm 0.2 0.2
BE35.31-P-1002-04C Rear axle housing expansion (spread dimension) when installing circlip mm 0.3 0.3
BE35.31-P-1003-04C Setting for rear axle housing expansion (spread dimension) mm 0.11...0.17 0.11-0.17
TEST VALUES FOR REAR AXLE HOUSING EXPANSION

Number Designation Model 129.060 Model 170.444/445/447/ 449 Model 201.018/023/024/ 122/126, with (code 450) as of 01.11.88
BE35.31-P-1001-04C Rear axle housing expansion (spread dimension) for circlip removal mm 0.2 0.2 0.2
BE35.31-P-1002-04C Rear axle housing expansion (spread dimension) when installing circlip mm 0.3 0.3 0.3
BE35.31-P-1003-04C Setting for rear axle housing expansion (spread dimension) mm 0.11-0.17 0.11-0.17 0.11-0.17
TEST VALUES FOR REAR AXLE HOUSING EXPANSION

Number Designation Model 201.028/029/035/036/128 Model 202.018/078/ 120/121/122/ 125/182 with (code 450), model 202.018/020/ 022/120/121/125 with (code 211) ASD Model 202.020/022/023/ 024/025/026/028/029/ 080/081/082/083/086/ 087/088/089/ 128/188, model 202.085 with automatic 5-speed transmission, Model 202.134/194 except code 450
BE35.31-P-1001-04C Rear axle housing expansion (spread dimension) for circlip removal mm 0.2 0.2 0.2
BE35.31-P-1002-04C Rear axle housing expansion (spread dimension) when installing circlip mm 0.3 0.3 0.3
BE35.31-P-1003-04C Setting for rear axle housing expansion (spread dimension) mm 0.11-0.17 0.11-0.17 0.11-0.17
TEST VALUES FOR REAR AXLE HOUSING EXPANSION

Number Designation Model 203.035/045/ 061/235/245/ 261/735/745/ 747, Model 203.004/204 except code 450 Model 208.335/344/ 345/347/348/ 435/444/445/ 447/448 Model 210.010/020/ 035/037/048/ 061/062/210/ 235/237/248/ 261/262/610
BE35.31-P-1001-04C Rear axle housing expansion (spread dimension) for circlip removal mm 0.2 0.2 0.2
BE35.31-P-1002-04C Rear axle housing expansion (spread dimension) when installing circlip mm 0.3 0.3 0.3
BE35.31-P-1003-04C Setting for rear axle housing expansion (spread dimension) mm 0.11-0.17 0.11-0.17 0.11-0.17
TEST VALUES FOR REAR AXLE HOUSING EXPANSION

Number Designation Model 210.003/004 with code 450 Model 210.007 except code 450
BE35.31-P-1001-04C Rear axle housing expansion (spread dimension) for circlip removal mm 0.2
BE35.31-P-1002-04C Rear axle housing expansion (spread dimension) when installing circlip mm 0.3
BE35.31-P-1003-04C Setting for rear axle housing expansion (spread dimension) mm 0.11-0.17
TEST VALUES FOR CONNECTING FLANGE/DIFFERENTIAL HOUSING

Number Designation Model 124 Model 129 Model 170 Model 201
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 0.03...0.3
TEST VALUES FOR CONNECTING FLANGE/DIFFERENTIAL HOUSING

Number Designation Model 202 Model 203.006/016/ 064/206/216/ 264/706, Model 203.004/204 with code 450 Model 208 Model 210
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 0.03...0.3
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 124 Model 129
BA35.31-P-1001-02A Bolt, end cover to rear axle differential Bolt+washer Nm 50 50
Flange bolt
(TORX, internal serrations)		 Stage 1 Nm 30 30
2nd stage ∠° 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 differential Nm 25 30
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 170 Model 201
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
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 differential Nm 25 25
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 202 Model 208
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
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 differential Nm 25 25
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 210
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
2nd stage ∠° 45
BA35.31-P-1002-02A Oil filler screw, rear axle differential Nm 50
BA35.31-P-1003-02A Oil drain screw for rear axle differential Nm 50
BA35.31-P-1005-02A Breather, rear axle differential Nm 50
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-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1002-02B Oil drain screw, rear axle differential Nm 50
BA35.31-P-1003-02B Breather, rear axle differential Nm 25
BA35.31-P-1004-02B Bolt, end cover to rear axle differential Bolt+washer Nm 50
Flange bolt
(TORX, multipoint socket)		 Stage 1 Nm 30
Stage 2 ∠° 45
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL HOUSING

Number Designation Model 203.006/007/008/064/206/ 207/208/264/ 706/707/708/ 764, Model 203.004/204 with code 450 up to 08/2002 Model 203.007/207/ with code 450
BA35.31-P-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1002-02B Oil drain screw, rear axle differential Nm 50
BA35.31-P-1003-02B Breather, rear axle differential Nm 25
BA35.31-P-1004-02B Bolt, end cover to rear axle differential Bolt+washer Nm 50
Flange bolt
(TORX, multipoint socket)		 Stage 1 Nm 30
Stage 2 ∠° 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-1001-02B Oil filler screw, rear axle differential Nm 50
BA35.31-P-1002-02B Oil drain screw, rear axle differential Nm 50
BA35.31-P-1003-02B Breather, rear axle differential Nm 25
BA35.31-P-1004-02B Bolt, end cover to rear axle differential Bolt+washer Nm -
Flange bolt
(TORX, multipoint socket)		 Stage 1 Nm 30
Stage 2 ∠° 45
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL GEAR SET

Number Designation Model 124.003/004/007/019/022/023/ 026/027/030/040/042/043/050/ 060/062/079/082/083/090, Model 124.104 /107 as of 01.05.94, Model 124.127/128/129/130/131/133, Model 124.186 as of 01.03.94, except (Code 450) Model 124.188/190/191/193/226/230/ 290/330/333/393 Model 124.020/021/080/081/ 120/125/126/180/ 185/186, with (code 450) as of 01.11.88
BA35.31-P-1001-03C Retaining bolt, ring gear to differential case Nm 85 85
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL GEAR SET

Number Designation Model 129.060 Model 170.444/445/447/449 Model 201.018/023/024/ 122/126, with (code 450) as of 01.11.88
BA35.31-P-1001-03C Retaining bolt, ring gear to differential case Nm 85 85 85
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL GEAR SET

Number Designation Model 201.028/029/ 035/036/128 Model 202.018/078/120/121/122/125/182 with (code 450) Model 202.018/020/022/120/121/125 with ASD (code 211a) Model 202.020/022/023/024/ 025/026/028/029/080/ 081/082/083/086/087/ 088/089/128/188, Model 202.085 with auto. 5-speed transmission, Model 202.134/194 except code 450
BA35.31-P-1001-03C Retaining bolt, ring gear to differential case Nm 85 85 85
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL GEAR SET

Number Designation Model 203.035/045/ 061/235/245/ 261/735/745/ 747, Model 203.004/204 except Code 450 Model 208.335/344/ 345/347/348/ 435/444/445/ 447/448
BA35.31-P-1001-03C Retaining bolt, ring gear to differential case Nm 85 85
TORQUE SPECIFICATION REAR AXLE DIFFERENTIAL GEAR SET

Number Designation Model 210.003/004 with Code 450 Model 210.007 except code 450 Model 210.010/020/ 035/037/048/ 061/062/210/ 235/237/248/ 261/262/610
BA35.31-P-1001-03C Retaining bolt, ring gear to differential case Nm 85 85
TORQUE SPECIFICATION RING CYLINDER

Number Designation Model 124 Model 129 Model 201 Model 202
BA35.41-P-1001-01A Bolt to ring cylinder Nm 25 25 25 25
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 124.003/004/007/ 019/022/023/026/027/ 030/040/042/043/050/ 060/062/079/082/083/ 090/127/128/129/13/ 188/190/191/193/2/3 without (code 211) ASD Model 124.104/107 as of 01.05.94 without (code 211) ASD Model 124.003/004/007/ 019/022/023/026/027/ 030/040/042/043/050/ 060/062/079/082/083/ 090/127/128/129/13/ 188/190/191/193/2/3 with (code 211) ASD Model 124.104/107 as of 01.05.94 with (code 211) ASD
BF35.31-P-1001-01B Filling capacity Rear axle differential Liters 1.1 1.1
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A BB00.40-P-0235-00A
Sheet BB00.40-P-0235-07A -
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 124.020/021/080/ 081/120/125/126/180/ 185/186 with (code 211) ASD Model 124.020/021/080/ 081/120/125/126/180/ 185/186, without (code 211) ASD, with (code 450) taxi version as of 01.11.88
BF35.31-P-1001-01B Filling capacity Rear axle differential Liters 1.1 1.1
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A BB00.40-P-0235-00A
Sheet - BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 124.186 as of 01.03.94, without (code 211) ASD, except (code 450) taxi version
BF35.31-P-1001-01B Filling capacity Rear axle differential Liters 1.1
Specifications for Operating Fluids Sheet BB00.40-P-0235-00A
Sheet BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 129.060 without (Code 211) ASD Model 129.060 with (Code 211) ASD
BF35.31-P-1001-01C Filling capacity Rear axle differential Liters 1.1 1.1
Specifications for Operating Fluids Sheet BB00.40-P-0235-00A -
Sheet BB00.40-P-0235-07A BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 202.018/020/ 022/120/121/125, with (code 211) ASD Model 202.018/078/ 120/121/122/ 125/182, without (code 211) ASD, with (code 450) taxi version 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 differential Liters 1.1 1.1 1.1
Specifications for Operating Fluids Sheet - BB00.40-P-0235-00A BB00.40-P-0235-00A
Sheet BB00.40-P-0235-07A BB00.40-P-0235-07A BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 210.003/004 with code 450, 210.007 except code 450 Model 210.010/020/ 035/037/048/06 1/062/210/235/ 237/248/261/262 /610
BF35.31-P-1001-01E Filling capacity Rear axle differential Liters 1.1 1.1
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 170.444/445/447/ 449
BF35.31-P-1001-01F Filling capacity Rear axle differential Liters 1.1
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

Number Designation Model 201.018/023/ 024/028/029/035 /036/122/126/ 128, with (code 211) ASD Model 201.018/023/ 024/122/126, without (code 211) ASD, with (code 450) taxi version as of 01.11.88 Model 201.028/029/ 035/036/128 without (code 211) ASD
BF35.31-P-1001-01G Filling capacity Rear axle differential Liters 1.1 1.1 1.1
Specifications for Operating Fluids Sheet - BB00.40-P-0235-00A BB00.40-P-0235-00A
Sheet BB00.40-P-0235-07A - -
FLUID SPECIFICATION REAR AXLE DIFFERENTIAL

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

Number Designation Model 203.035/045/235/ 245/735/745/747, Model 203.061/261 up to 08/2002, Model 203.004/204 except code 450 up to 08/2002
BF35.31-P-1001-01K Filling capacity Rear axle differential Liters 1.1
Specifications for Operating Fluids Sheet BB00.40-P-0235-07A
Fig 2: Identifying Assembly Stand (129 589 00 31 00)
G04635163
Fig 3: Identifying Spreader (126 589 00 31 00)
G04635164
Fig 4: Identifying Contact Arm (126 589 08 21 00)
G04635165
Fig 5: Identifying Spring Compressor (116 589 18 61 00)
G04635166
Fig 6: Identifying Puller (123 589 08 33 00)
G04635167
Fig 7: Identifying Socket Screw Wrench (129 589 01 07 00)
G04635168
Fig 8: Identifying Socket (126 589 02 09 00)
G04635169
Fig 9: Identifying Puller (129 589 01 33 00)
G04635170
Fig 10: Identifying Removal And Installation Tool (201 589 02 43 00)
G04635171
Fig 11: Identifying Two-Armed Puller (000 589 88 33 00)
G04635172
Fig 12: Identifying Puller (001 589 50 33 00)
G04635173
Fig 13: Identifying Extension (000 589 63 34 00)
G04635174
Fig 14: Identifying Collet Chuck (000 589 34 34 00)
G04635175
Fig 15: Identifying Dial Indicator Holder (363 589 02 21 00)
G04635176
Fig 16: Identifying Measuring Plate (601 589 00 23 00)
G04635177
Fig 17: Identifying Measuring Device (124 589 14 21 00)
G04635178
Fig 18: Identifying Measuring Device (126 589 00 21 00)
G04635179
Fig 19: Identifying Dial Indicator (000 589 38 19 00)
G04635180
Fig 20: Identifying Installer (116 589 11 61 00)
G04635181
Fig 21: Identifying Drift (124 589 02 15 00)
G04635182
Fig 22: Identifying Drift (208 589 00 15 00)
G04635183
Fig 23: Identifying Torque Meter (001 589 49 21 00)
G04635184
Fig 24: Identifying Spring Compressor (115 589 04 61 00)
G04635185
Fig 25: Identifying Drift (126 589 00 15 00)
G04635186
Fig 26: Identifying Drift (126 589 04 15 00)
G04635187
Fig 27: Identifying Tooth Backlash Gauge (201 589 03 21 00)
G04635188
Fig 28: Identifying Connecting Piece (100 589 02 59 00)
G04635189
Fig 29: Identifying Removal And Installation Tool (116 589 01 62 00)
G04635190
Fig 30: Identifying Open-End Wrench (140 589 00 01 00)
G04635191
Fig 31: Identifying Puller (000 589 65 33 00)
G04635192
Fig 32: Identifying Remote Thermometer (124 589 07 21 00)
G04635193
Fig 33: Identifying Extraction Tool (129 589 02 33 00)
G04635194
Fig 34: Identifying Drift (124 589 01 15 00)
G04635195
Fig 35: Identifying Sealant Gun (112 589 00 25 00)
G04635196
Fig 36: Identifying Drift (140 589 14 15 00)
G04635197
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1009-02A Pliers for circlip, inner
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
Fig 37: Identifying Socket Wrench Bit (126 589 02 09 00)
G04734744
Fig 38: Identifying Drift (126 589 00 15 00)
G04636356
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