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Boot cap on joint ring removal and installation - AR35.30-P-0661-01P

FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 209.316 with transmission 716 Model 209.365/465 Model 209.316 with transmission 722 Model 209.341/342/343/361
BF35.30-P-1001-01A Filling capacity Inner constant-velocity joint g 120 120 100
BF35.30-P-1002-01A Filling capacity Outside constant velocity joint g 120 140 100
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 209.372/375/376/377/472/475/476/477 Model 209.441/442 Model 209.461 with Transmission 716
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 140 120 120
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 209.461 with Transmission 722
BF35.30-P-1001-01A Filling capacity Inner constant-velocity joint g 85
BF35.30-P-1002-01A Filling capacity Outside constant velocity joint g 100
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 203.004/204 except code 450 Model 203.035/045/061/081/235/245/261/281/735/745 Model 203.004/204 with code 450, inserted axle shaft Model 203.004/204 with code 450, screwed axle shaft
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 120 140 120
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 203.084/284 Model 203.747 with Transmission 716 Model 203.747 with Transmission 722
BF35.30-P-1001-01D Filling capacity Inner constant-velocity joint g 120 100 85
BF35.30-P-1002-01D Filling capacity Outside constant velocity joint g 120 120 100
FLUID SPECIFICATION REAR AXLE SHAFT

Number Designation Model 203.087/092/287/292
BF35.30-P-1001-01D Filling capacity Inner constant-velocity joint g 120
BF35.30-P-1002-01D Filling capacity Outside constant velocity joint g 120
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1011-02A Clamping pliers

    Remove boot cap 

  1. Using protective jaw pads, clamp rear halfshaft into vice.
  2. Using a commercially-available bow saw, cut into the boot cap (37i) at an angle of approximately 45° to form an angled notch.

    IMPORTANT Avoid damaging the joint ring (37c).

    Fig 1: Cutting Into The Boot Cap At An Angle Of Approximately 45 Degrees
    G04734677
  3. Use a screwdriver to lift the notched area.
  4. Starting at the raised end, use suitable pliers to rotate the cap seal (37i) until it is possible to lift the cap seal (37i) from the joint ring.

    IMPORTANT When rotating on the boot cap (37i) avoid allowing the rear halfshaft to drop out of the joint ring before the relative alignment positions of the components have been marked.

  5. Remove hose clamps (37k).
  6. Pull boot with boot cap (37i) from joint ring (37c) and slide down rear halfshaft.

    IMPORTANT If both boots are being replaced, the opposite boot can be slid over driveshaft.

    Fig 2: Removing Boot And Clamp
    G04734678

    7. Install boot cap. 

  7. Replace O-ring of joint ring (37c).

    NOTES Do not grease or oil the O-ring, as this might cause the cap seal (37i) to turn on the joint ring (37c).

  8. Mount cup seal (37i) and slide all the way onto the joint ring (37c). If necessary, drive fully home by tapping gently with a plastic mallet.
  9. Apply four blows at 90° intervals to seat the cap seal (37i) in the groove running around the periphery of the joint ring.
    Fig 3: Locating Cup Seal, Joint Ring And Plastic Mallet
    G04734679
  10. Use even blows with a suitable hammer to drive the cap seal (37i) into the groove extending along the periphery of the joint ring.

    IMPORTANT Ensure that the boot cap (37i) seats properly.

    Fig 4: Driving The Cap Seal Into The Groove Extending Along The Periphery Of The Joint Ring
    G04734680
  11. Continue to apply the peen and use even blows of the plastic hammer to drive the cap seal (37i) firmly into the groove.
    Fig 5: Driving The Cap Seal Firmly Into The Groove
    G04734681

    FLUID SPECIFICATION .

  12. Fill joint with new grease
  13. Slide boot (37l) onto boot cap.

    IMPORTANT Ensure that the ridge (arrow) on the boot (37l) is resting between the ridges on the boot cap (37i).

    IMPORTANT After the boot (37l) is slid on, no grooves on the rear halfshaft should be visible at the end with the smaller diameter, this indicates that the ridge (37l) on the boot is in the first groove.

    Fig 6: Locating Slide Boot And Cap Seal
    G04734682
  14. Install hose clamps (37k).

    IMPORTANT Make sure that dimension (a) 2 up to 2.5 mm (measured at inside)  is not undercut or exceeded.

    Fig 7: Installing Hose Clamps
    G04734683
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