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Home >> Mercedes Benz >> 2006 >> C350 Base, Standard >> Repair and Diagnosis >> Suspension >> Rear Suspension >> Rear Axle -- Testing & Repair -- 203 Chassis - 1 Of 2 >> Testing & Repair >> Remove/install complete rear axle - AR35.10-P-0010P

Remove/install complete rear axle - AR35.10-P-0010P

MODEL 203, 209.3 /4 

Fig 1: Identifying Complete Rear Axle Remove/Install Components - Model 203, 209.3 /4 (1 Of 2)
G04734621
Fig 2: Identifying Complete Rear Axle Remove/Install Components - Model 203, 209.3 /4 (2 Of 2)
G04734622
MODIFICATION NOTES

20.3.07 Wheel bolt Model 209 *BA40.10-P-1001-01A 
REMOVINGINSTALLING Remove/install    
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A
NOTES Notes on self-locking nuts and bolts All models AH00.00-N-0001-01A
NOTESInstallation 
CAUTION: important note: The thread in the frame floor assembly must be recut and blown out on a mandatory basis as the remaining adhesive remains prevent the necessary preload force of the bolt being achieved, despite the specified torque and specified rotational angle being achieved.
If this is not observed then the faulty bolt preload force will cause transverse forces to be applied to the bolt, which may cause the bolt to fracture
    
NOTES While working on the rear axle, care must be taken to ensure that the surface of aluminum components do not get any scratches, cracks and notches. Otherwise the service life of the parts will be affected    
IMPORTANTInstallation  Only tighten nuts and bolts of chassis components when vehicle is in a ready-to-drive condition.    
1.1 Fold forward rear seat cushion Model 203.0/2/7, 209.3/4 with through-loading feature code 287  
1.2 Remove rear seat cushion Model 203.0 without through-loading feature, code 287 AR91.12-P-1020PC
    Model 209.3/4 AR91.12-P-1020QA
2 Disconnect rear brake cables from idler lever (110d) and idler lever housing (110c) SPECIAL TOOL Fig 3
3 Remove wheels    
REFER TO MAINTENANCE Remove/install wheels, rotate if necessary   AP40.10-P-4050Z
    TORQUE SPECIFICATION *BA40.10-P-1001-01A 
4 Remove rear diagonal struts Model 209.4
NOTESInstallation:  The diagonal struts may only be installed when the vehicle has its wheels on the ground in order to avoid stresses.
TORQUE SPECIFICATION		 *BA62.30-P-1004-01A 
5 Remove exhaust system (105) from flange connection Engine 111.951 in model 203.035/235/735
Engine 111.955 in model 203.045/245/745
Engine 111.981 in model 203.747		 AR49.10-P-7000PR
    Engine 112 in model 203, 209
Engine 113.968 in model 209.375/475
Engine 113.987 in model 209.376 up to 23.4.04
Engine 113.987 in model 209.476
Engine 156.982 in model 209.477		 AR49.10-P-7000PV
    Engine 611.962 in model 203.004/006/204/206/706
Engine 612.962 in model 203.016/216
Engine 612.967 in model 209.316		 AR49.10-P-7000PP
    Engine 612.990 in model 203.018/218/718 AR49.10-P-7000PF
    Engine 646 in model 203, 209 AR49.10-P-7000PM
    Engine 113 in model 203.076/276
Engine 113.987 in model 209.376 as of 24.4.04
Engine 156.982 in model 209.377		 AR49.10-P-7000AC
    Engine 271.940 in model 203.042/242/742
Engine 271.940 in model 209.342/442
Engine 271.946 in model 203.046/246/746
Engine 271.948 in model 203.040 /240 /740
Engine 271.921 in model 203.730
Engine 271.955 in model 209.341/441		 AR49.10-P-7000QK
    Engine 271.942 in model 203, 209.3 AR49.10-P-7000QD
    Engine 272 in model 203.052/054/056/087/092/252/254/256/287/292/752/756 AR49.10-P-7000QB
    Engine 272 in model 209.354/356/454/456
Engine 273 in model 209.372/472		  
6 Remove rear exhaust shielding plate (105c) IMPORTANT To do this, lift front exhaust shielding plate  
7 Unscrew mounting bolts of propeller shaft intermediate bearing (106a) TORQUE SPECIFICATION *BA41.40-P-1001-01A 
8 Detach rear propeller shaft (106) from rear differential assembly IMPORTANT Tie up rear propeller shaft (106) to one side. The flexible coupling remains on the rear propeller shaft (106). AR41.10-P-0050-03EA
    IMPORTANTInstallation:  Attach rear propeller shaft (106) to rear axle differential. AR41.10-P-0050-04EA
    NOTES Install new self-locking nuts to prevent propeller shaft from working loose.
TORQUE SPECIFICATION		 *BA41.10-P-1002-01A 
9 Remove torsion bar (6r) IMPORTANT The link rods (6k) remain on the wheel carriers. AR32.20-P-0315P
10 Unscrew fixed brake calipers from wheel carriers IMPORTANT Attach fixed brake caliper to the spring tower using a suitable wire.
TORQUE SPECIFICATION		 *BA42.10-P-1001-01A 
11 Disconnect electrical connectors (2) of rear axle rpm sensor on vehicle floor    
12 Remove rear springs (6i)   AR32.20-P-0230P
13 Unscrew shock absorbers (6j) on spring control arms IMPORTANT To do this, remove cover of spring control arm (6g).
TORQUE SPECIFICATION		 *BA32.25-P-1003-03A 
14 Unscrew nuts (131a) of underfloor paneling (131)    
15 Support rear axle using transmission platform IMPORTANT Secure against falling.
Transmission platform, refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
16 Unscrew rear axle suspension bolts (1c, 1d) IMPORTANTInstallation:  Recut thread in frame floor assembly and blow out. Use new bolts and replace shims (1) on stabilizer bar mounts (6s).
TORQUE SPECIFICATION		 *BA35.10-P-1001-01A 
    TORQUE SPECIFICATION *BA35.10-P-1002-01A 
17 Lower rear axle while simultaneously pulling to the rear. NOTES On vehicles with level control when lowering ensure that the level controller is not damaged in order to ensure its function.  
18 Install in the reverse order    
INSPECT Checking     
19 Check headlamp adjustment    
REFER TO MAINTENANCE Check and correct headlamp adjustment   AP82.10-P-8260P
TORQUE SPECIFICATION CROSSMEMBER AND FRONT REINFORCEMENT

Number Designation Model 209.4
BA62.30-P-1004-01A Bolt, diagonal strut Nm 80
TORQUE SPECIFICATION REAR AXLE SHOCK ABSORBER

Number Designation Model 203 Model 209
BA32.25-P-1003-03A Self-locking nut for attaching shock absorber to spring control arm   Nm 55 50
M10 Nm - -
TORQUE SPECIFICATION REAR AXLE CARRIER

Number Designation Model 203 Model 209
BA35.10-P-1001-01A Self-locking bolt, front rear axle carrier rubber mount to frame floor     Nm - -
with bolt Stage 1 Nm - -
Flange ø 24mm Stage 2 ∠ ° - -
with bolt Stage 1 Nm 40 40
flange ø 26mm Stage 2 ∠ ° 90 90
BA35.10-P-1002-01A Self-locking bolt, rear axle carrier rear rubber mount to frame floor     Nm - -
with bolt Stage 1 Nm - -
Flange ø 24mm Stage 2 ∠ ° - -
with bolt Stage 1 Nm 40 40
flange ø 26mm Stage 2 ∠ ° 90 90
TORQUE SPECIFICATION WHEELS

Number Designation Model 203 Model 209 with code P98
BA40.10-P-1001-01A Wheel bolt Nm 110 130
TORQUE SPECIFICATION PROPELLER SHAFT

Number Designation Model 203 Model 209
BA41.10-P-1002-01A Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential. M10 Nm 40 36
M12 Nm 60 58
TORQUE SPECIFICATION PROPELLER SHAFT INTERMEDIATE BEARING

Number Designation Model 203 Model 209
BA41.40-P-1001-01A Bolt, propeller shaft intermediate bearing to frame floor assembly Self-tapping screw Nm - -
Bolt with washer Nm - -
Bolt with collar and self-centering tip Nm 30 30
Bolt with collar and without self-centering tip Nm - -
TORQUE SPECIFICATION FIXED CALIPER AT REAR

Number Designation Model 203 except model 203.076/276 Model 209.376/476 as of 24.4.04 Model 209.377/477 (4-piston fixed brake caliper) Model 203.076/276 Model 209.376/476 up to 24.4.04 (2-piston fixed brake caliper)
BA42.10-P-1001-01A Self-locking bolt, fixed caliper to wheel carrier Nm 55 85 55
TORQUE SPECIFICATION FIXED CALIPER AT REAR

Number Designation Model 209 except 209.376/377/476/477
BA42.10-P-1001-01A Self-locking bolt, fixed caliper to wheel carrier Nm 55
Fig 3: Identifying Snap-Release Tool (129 589 11 63 00)
G04734623
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