Remove/install end cover at rear axle differential - AR35.31-P-0554AF

Rear axle differential dia. 210 in model 203.018 /065 /218 /265 /718, 209.316, 209.375 /376 /475 /476 up to 23.4.04 rear axle center assembly 210E

Rear axle differential dia. 187 in MODELS 209.341 /342 /343 /361 /441 /442 /461

Fig 1: Identifying Rear Axle Differential, End Cover And Bolts - Dia. 210 And 187

	Removal
	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
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Raise vehicle with lifting platform		AR00.60-P-1000P
2	Drain oil from rear axle differential (1)		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
			*BA35.31-P-1002-02B
	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 (1)	Model 209	AR35.31-P-0520P
		Model 203	AR35.31-P-0520PF
4	Clamp rear axle differential (1) in assembly stand.		AR35.31-P-0540-06B
			Fig 6
			Fig 7
			Fig 8
5	Unscrew bolts (3) from end cover (2), remove end cover (2)	Loosen end cover (2) using screwdriver or assembly lever (see picture).
	Install
6	Attach end cover (2)	Model 209	AR35.31-P-0550-28CA
		Model 203	AR35.31-P-0550-28CF
			*BA35.31-P-1004-02B
			Figure
		Sealant	*BR00.45-Z-1013-01A
7	Replace rear axle center assembly breather (1)		*BA35.31-P-1003-02B
8	Remove rear axle center assembly (1) from assembly block.
9	Install rear axle differential (1).	Model 209	AR35.31-P-0520P
		Model 203	AR35.31-P-0520PF
10	Pour oil into the rear axle differential (1)		AR35.31-P-0520-03I
			*BF35.31-P-1001-01K
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
			*BA35.31-P-1001-02B
	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04	BT35.31-P-0015-01A
	Check
11	Check rear axle differential (1) for leaks	Carry out visual inspection.

REAR AXLE DIFFERENTIAL HOUSING

Number	Designation				Model 203.018/065/218/265/718
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 center assembly			Nm	25
BA35.31-P-1004-02B	Bolt, end cover to rear axle differential	Bolt+washer		Nm	50
		Flange bolt	Stage 1	Nm	30
		(TORX, multipoint socket)	Stage 2	∠ °	45

REAR AXLE DIFFERENTIAL HOUSING

Number	Designation				Model 209.316, Model 209.375/376/475/476 up to 23.4.04
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 center assembly			Nm	30
BA35.31-P-1004-02B	Bolt, end cover to rear axle differential	Bolt+washer		Nm	-
		Flange bolt	Stage 1	Nm	30
		(TORX, multipoint socket)	Stage 2	∠ °	45

REAR AXLE DIFFERENTIAL HOUSING

Number	Designation				Model 209.341/342/343/361/441/442/461
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 center assembly			Nm	25
BA35.31-P-1004-02B	Bolt, end cover to rear axle differential	Bolt+washer		Nm	50
		Flange bolt	Stage 1	Nm	30
		(TORX, multipoint socket)	Stage 2	∠ °	45

REAR AXLE DIFFERENTIAL

Number	Designation			Model 203.018/065/218/265/718	Model 209.341/342/343/361/441/442/461	Model 209.316, Model 209.375/376/475/476 up to 23.4.04
BF35.31-P-1001-01K	Filling capacity	Rear axle differential	Liters	1.6	1.0	1.6
BF35.31-P-1001-01K	Filling capacity	Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	BB00.40-P-0235-07A	BB00.40-P-0235-07A

Fig 2: Identifying Sealant Gun (112 589 00 25 00)

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

Fig 4: Identifying Supports (211 589 01 31 00)

Fig 5: Identifying Supports (220 589 01 63 00)

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Sealant	A 003 989 98 20
BR00.45-Z-1061-01A	Sealant, Omnifit 100H (50 g)	-
BR00.45-Z-1046-04A	Cleaning spray, Loctite 7063 (150ml)	A 001 986 71 71 10

Fig 6: Identifying Assembly Stand (129 589 00 31 00)

Fig 7: Identifying Supports (211 589 01 31 00)

Fig 8: Identifying Supports (220 589 01 63 00)