Replace radial sealing ring at drive pinion gear (with rear axle differential installed) - AR35.31-P-0530PI

MODEL 203.040 /042 /043 /046 /052 /240 /242 /243 /246 /252 /730 /740 /742 /743 /746 Rear axle differential dia. 187

MODEL 203.054 /056 /254 /256 /756, 209.354 /356 /454 /456 Rear axle differential dia. 200

Fig 1: Identifying Hexagon Collar Nut, Exhaust System And Front Propeller Shaft - Dia. 187 And 200

	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
1	Raise vehicle		AR00.60-P-1000P
2	Drain oil from rear axle differential		AR35.31-P-0520-06I
	Universal hypoid gear oils (SAE 85 W-90)	Sheet 235.7 Model 203.040/042/043/046/240/242/243/246/740/742/743/746 with rear axle differential 187FE up to production period 18.1.04 ↓	BB00.40-P-0235-07A
	Oil filler/drain screw on rear axle differential modified	up to 18.1.04	BT35.31-P-0015-01A
		Oil drain screw, rear axle differential	*BA35.31-P-1002-02B
		Torque wrench	Figure
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
		Omnifit sealing compound 100H (50 g)	*BR00.45-Z-1061-01A
3	Remove exhaust system (105) from flange connection
		Model 203.043/243/743	AR49.10-P-7141QD
		Model 203.040/042/046/240/242/246/740/742/746	AR49.10-P-7000QK
		Model 203.052/054/056/252/254/256/756, 209.354/356/454/456	AR49.10-P-7000QB
4	Remove exhaust heat shield (105c)
5	Remove bolts for propeller shaft intermediate bearing (106a).	Mark the installation position of the propeller shaft intermediate bearing (106a) before loosening. Installation: Attach flexible coupling to rear axle differential first before tighten bolts of propeller shaft intermediate bearing (106a). Bolt, propeller shaft intermediate bearing to frame floor assembly	*BA41.40-P-1001-01A
		Torque wrench	Figure
6	Remove rear propeller shaft (106) from rear axle differential	The flexible coupling remains on the rear propeller shaft (106).	AR41.10-P-0050-03EA
	Attach rear propeller shaft (106) to rear axle differential		AR41.10-P-0050-04EA
		If the fitting sleeves are stuck, see: ↓
		Loosen fitting sleeves on flexible couplings.	AR41.10-P-0050-09DA
	Drift for loosening fitting sleeves in flex disks.		WF58.50-P-4110-01A
		Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential.	*BA41.10-P-1002-01A
		Torque wrench	Figure
7	Detach rear propeller shaft (106) from front propeller shaft (106c)	Installation: Observe any markings made previously; see: ↓
		Connect sections of propeller shaft	AR41.10-P-0050-05DA
		Before assembling the front and rear propeller shaft (106c, 106), remove any dirt and refresh the grease coating in order to prevent friction between the propeller shafts.
	General lubricating grease	Sheet 261.0	BB00.40-P-0261-00A
8	Loosen/remove twelve-point / hexagon collar nut (40)	Do not remove the collar protection when loosening the twelve-point / hexagon collar nut (40). Installation: Fit a new twelve-point / hexagon collar nut (40). Installation: See: ↓ Secure twelve-point / hexagon collar nut on drive pinion gear joint flange	AR35.31-P-0530-01B
	Chisel for securing collar nut on joint flange		WF58.50-P-3531-01A
		Collar nut of joint flange to drive pinion gear	*BA35.31-P-1001-01A
		Pin wrench Rear axle differential, 187 mm dia:	Figure
		Socket Rear axle differential dia. 200 mm:	Figure
		Socket	Fig 7
		Torque wrench	Figure
9	Detach joint flange (41).	Puller	Figure
10	Press radial sealing ring (42) out of rear axle differential using a suitable tool	Installation: Fit a new radial sealing ring (42) to prevent leaks.
		Installation: Coat the lip with universal hypoid gear oil.
	Universal hypoid gear oils (SAE 85 W-90)	Sheet 235.7	BB00.40-P-0235-07A
		Installation: Drive the radial sealing ring (42) evenly into the rear axle differential. Then make sure that the radial sealing ring (42) is seated correctly.
		Drift	Figure
11	Install in the reverse order
	Checking
12	Check oil level in rear axle center assembly, correct if necessary	In the interest of better fuel economy, avoid mixing old universal hypoid gear oil with new FE hypoid gear oil.	AR35.31-P-0520-03I
	Universal hypoid gear oils (SAE 85 W-90)	Sheet 235.7 Model 203.040/042/043/046/240/242/243/246/740/742/743/746 with rear axle differential 187FE up to production period 18.1.04 ↓	BB00.40-P-0235-07A
	Oil filler/drain screw on rear axle differential modified	up to 18.1.04	BT35.31-P-0015-01A
		Oil filler screw for rear axle differential	*BA35.31-P-1001-02B
		Filling capacity of rear axle differential	*BF35.31-P-1001-01K
		Torque wrench	Figure
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
		Omnifit sealing compound 100H (50 g)	*BR00.45-Z-1061-01A
13	Check rear axle differential for leaks	Carry out visual inspection.

REAR AXLE DIFFERENTIAL GEAR SET

Number	Designation		Model 203.008/020/040/042/043/046/052/054/056/081/084/087/092/208/220/240/242/243/246/252/ 254/256/281/284/287/292/708/730/742/743/740/746/756, Model 203.004/061/204/261 as of 09/2002	Model 209.308/320/341/342/343/354/356/361/420/441/442/454/456/461
BA35.31-P-1001-01A	Collar nut, joint flange to drive pinion	Nm	150	150

REAR AXLE DIFFERENTIAL HOUSING

Number	Designation		Model 203.020/040/052/054/056/220/240/243/252/254/256/730/743/756
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

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

REAR AXLE DIFFERENTIAL HOUSING

Number	Designation		Model 209.308/320/354/356/420/454/456
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

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
BA41.10-P-1002-01A		M12	Nm	50	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	-	-

REAR AXLE DIFFERENTIAL

Number	Designation			Model 203.040/042/043/046/052/081/084/087/092/240/242/243/246/252/281/284/287/292/707/730/740/742/743/746, Model 203.004/061/204/261, as of 09/2002, Model 203.007/207 without taxi version
BF35.31-P-1001-01K	Filling capacity	Rear axle center assembly	Liters	1.0
BF35.31-P-1001-01K	Filling capacity	Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A

Fig 2: Identifying Torque Wrench (001 589 66 21 00)

Fig 3: Identifying Pin Wrench (129 589 01 07 00)

Fig 4: Identifying Puller (129 589 01 33 00)

Fig 5: Identifying Drift (140 589 14 15 00)

Fig 6: Identifying Wrench Socket (126 589 02 09 00)

Fig 7: Identifying Wrench Socket (203 589 01 09 00)

REPAIR MATERIALS

Number	Designation	Order number
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