Constant-velocity joint or rubber boot on rear halfshaft - removal and installation - AR35.30-P-0661P

MODEL 203.004 /204 except CODE (450) Taxi version

MODEL 203.035 /045 /061 /081 /084 /235 /245 /261 /281 /284 /735 /745 /747

MODEL 203.087 /092 /287 /292, 209.3 /4

Fig 1: Identifying Constant-Velocity Joint Or Rubber Boot On Rear Halfshaft Remove/Install Components

	Remove/install
1	Remove rear axle shaft (37a)	Model 203, 209.308 /341 /342 /343 / 361 /365 /441 /442 /461 /465, model 209.375/376 /475 /476 up to 23.4.04	AR35.30-P-0620P
		Model 209.375 /376 /475 /476 as of 24.4.04 Model 209.372 /377 /472 /477	AR35.30-P-0620AC
		Model 209.354 /356 /454 /456	AR35.30-P-0620PI
		Model 209.320/ 420	AR35.30-P-0620PQ
2	Detach hose clamps (37k)	Installation: Replace hose clamps (37k), observing the width of the hose clamps.
3	Remove cup seal (37i) on inner joint ring (37c) and outer joint ring (37b)	Installation: Do not oil or grease O-ring (37n). Model 209	AR35.30-P-0661-01P
			*BF35.30-P-1001-01A
		Model 203	*BF35.30-P-1002-01A
			*BF35.30-P-1001-01D
			*BF35.30-P-1002-01D
			*WH58.30-Z-1011-02A
4	Dismantle constant-velocity joint		AR35.30-P-0661-03P
5	Press joint hub (37d) off the rear axle shaft (37a)		AR35.30-P-0661-02P
			Figure
			Figure
			Figure
	Shell halves (2 ea.) for pressing off and caulking the inner constant velocity joint.		WF58.50-P-3530-01A
	Staking tool for securing joint hub on rear halfshaft		WF58.50-P-3530-07P
6	Remove rubber boot (37l) from opposite constant velocity joint	Only if necessary. The rubber boot (37l) can be removed by way of the rear axle shaft (37a).
	Checking
7	Check constant velocity joints for wear	If the outer constant velocity joint is defective, then the rear axle shaft (37a) must be replaced.	AR35.30-P-0661-03P
8	Install in the reverse order

REAR AXLE SHAFT

Number	Designation			Model 209.461 with Transmission 716	Model 209.461 with Transmission 722
BF35.30-P-1001-01A	Filling capacity	Inner constant-velocity joint	g	100	85
BF35.30-P-1002-01A	Filling capacity	Outside constant velocity joint	g	120	100

REAR AXLE SHAFT

Number	Designation			Model 209.316 with transmission 716 Model 209.365/465	Model 209.316 with transmission 722
BF35.30-P-1001-01A	Filling capacity	Inner constant-velocity joint	g	120	120
BF35.30-P-1002-01A	Filling capacity	Outside constant velocity joint	g	120	140

REAR AXLE SHAFT

Number	Designation			Model 209.341/342/343/361	Model 209.372/375/376/377/472/475/476/477	Model 209.441/442
BF35.30-P-1001-01A	Filling capacity	Inner constant-velocity joint	g	100	150	100
BF35.30-P-1002-01A	Filling capacity	Outside constant velocity joint	g	100	140	120

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

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

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

Fig 2: Identifying Clamping Jaws (116 589 11 31 00)

Fig 3: Identifying Clamping Jaws (220 589 02 31 00)

Fig 4: Identifying Drift (116 589 15 15 00)

COMMERCIALLY AVAILABLE TOOLS

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