Remove/install front and rear rubber bushings in rear axle mount - AR35.10-P-0040P

MODEL 203, 209.3/ 4

Fig 1: Identifying Front And Rear Rubber Bushings In Rear Axle Mount Remove/Install Components

MODIFICATION NOTES

17.10.05

Repair information on the threaded connection of the rear axle carrier rubber mount to the frame floor assembly added

CAUTION: Important note: The thread in the frame floor assembly must be recut and blown out, as adhesive residue in the thread will prevent the bolt reaching the required preload force, despite having reached the specified torque and specified angle of rotation. 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.

	Remove/install
	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
Installation	CAUTION: Important note: The thread in the frame floor assembly must be recut and blown out, as adhesive residue in the thread will prevent the bolt reaching the required preload force, despite having reached the specified torque and specified angle of rotation. 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.
Installation	Tighten nuts and bolts of chassis components only when vehicle is in the ready-to-drive condition.
1	Remove rear wheels	See ↓
		Remove/install wheels, rotate if necessary.	AP40.10-P-4050Z
2	Detach underbody panel (131).	Avoid bending side member cover panels any more than absolutely necessary. Unscrew the four rear plastic nuts of the longitudinal member paneling (131a) and press down paneling.
3	Remove torsion bar (6).	Unbolt at linkage rods at bottom of torsion bar.
		Nut, linkage rod to torsion bar.	*BA32.20-P-1001-04C
		Bolt, bracket to torsion bar bracket.	*BA32.20-P-1006-04C
4	Unbolt fuel filter (115) from bracket	Do not disconnect fuel lines.
5	Remove exhaust heat shield (105c)	Lift front section and remove rear section.
6	Unscrew retaining bolts for propeller shaft intermediate bearing (106a)		*BA41.40-P-1001-01A
7	Disconnect propeller shaft (106) from rear axle center assembly at the flange	The flexible coupling remains on the propeller shaft.
		Tie propeller shaft to the side.
			*BA41.10-P-1002-01A
8	Support final-drive unit.		Fig 3
9	Unscrew front and rear rear-axle mounting bolts (1c, 1d) on one side	Installation: Recut and blow out thread in frame floor assembly.
		Use new bolts.
			*BA35.10-P-1001-01A
			*BA35.10-P-1002-01A
10	Remove torsion bar bracket (6b)	Installation: Ensure that intermediate disk (6c) is seated correctly.
11	Lower rear axle	Use lever to press rear axle away from tank when lowering. Lower the rear axle until the rubber mounts can be pulled in and out with the extractor and insertion device.
12	Extract rubber mount for front rear axle mount (1a)		AR35.10-P-0040-02P
13	Pull out rear rubber bushing for rear axle mount (1b)		AR35.10-P-0040-03P
14	Install in the reverse order

REAR AXLE STABILIZER BAR

Number	Designation		Model 203	Model 209
BA32.20-P-1001-04C	Nut for attaching link rod to torsion bar	Nm	40	40
BA32.20-P-1006-04C	Bolt, bracket to stabilizer bar bracket.	Nm	30	30

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

DRIVESHAFT

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
BA41.10-P-1002-01A		M12	Nm	60	58

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	-	-

Fig 2: Identifying Extraction And Insertion Tool (203 589 00 43 00)

Fig 3: Identifying Assembly Attachment (140 589 01 62 00)

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1002-06A	Lubricant	A 000 989 01 60