Remove/install rear axle differential - AR35.31-P-0520AC

Rear axle differential dia. 215

in model 203.076 /276, 209.372,

209.375 /376 as of 24.4.04,

209.377 /472,

209.475 /476 as of 24.4.04,

209.477

Fig 1: Identifying Rear Axle Differential Remove/Install Components - Dia. 215

MODIFICATION NOTES

10.8.06

Filling capacity, Specifications for Operating Fluids

Model 209.377/477

*BF35.31-P-1001-01K

	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
	While working on the rear axle care must be taken to ensure that the surface of all aluminum components do not get any scratches, cracks and notches. Otherwise the service life of the parts will be affected
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Lift/jack up vehicle		AR00.60-P-1000P
2	Remove exhaust shielding plates (105b, 105c)
3	Remove bolts from propeller shaft intermediate bearing (106a)	Installation: Assemble propeller shaft in correct position. Tighten bolts at propeller shaft intermediate bearing (106a) only after attaching flexible coupling at rear axle center assembly (50).
			*BA41.40-P-1001-01A
4	Remove rear propeller shaft (106) from rear axle differential (50)	The flexible coupling remains on the rear propeller shaft (106).	AR41.10-P-0050-03EA
		Installation: Attach rear propeller shaft (106) to rear differential assembly (50).	AR41.10-P-0050-04EA
			*BA41.10-P-1002-01A
5	Slacken flexible coupling fitted sleeves on flange.		AR41.10-P-0050-09DA
	Drift for loosening fitting sleeves in flex disks.		WF58.50-P-4110-01A
6	Remove right rear axle shaft (37)		AR35.30-P-0620AC
7	Remove heat sink from rear axle center assembly (50)	Only model 209.376 /476 as of 24.4.04.
			*BA35.31-P-1005-02B
8	Support rear axle differential (50)	Secure rear axle center assembly (50) to prevent it from falling down.	Figure
9	Unscrew bolts (50a) from the rear differential mounts		*BA35.10-P-1004-01A
10	Unscrew bolt (53) of the front center assembly suspension
		Installation: Attach front center assembly mounting.	AR35.10-P-0050-01A
			*BA35.10-P-1003-01A
11	Lower rear axle differential (50)	In the process detach rear axle differential (50) to the right of the left rear axle shaft (37). Ensure that no rear axle oil runs out when removing: ↓ Pull out/press in rear axle shaft (37) at rear axle center assembly (50).	AR35.30-P-0620-02P
12	Install in the reverse order
13	Replace breather	If necessary	*BA35.31-P-1003-02B
14	Check oil level in rear axle center assembly (50) and correct if necessary		AR35.31-P-0520-03I
			*BF35.31-P-1001-01K
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
			*BA35.31-P-1001-02B
	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04	BT35.31-P-0015-01A

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	-	-

REAR AXLE CARRIER

Number	Designation		Model 203	Model 209
BA35.10-P-1003-01A	Self-locking nut, rear axle differential at front to rear axle carrier	Nm	45	43
BA35.10-P-1004-01A	Self-locking bolt, rear axle differential at rear to rear axle carrier	Nm	110	110

REAR AXLE DIFFERENTIAL HOUSING

Number	Designation		Model 203.076/276 Model 209.375/376/475/476 as of 24.4.04 Model 209.372 472/477
BA35.31-P-1001-02B	Oil filler screw, rear axle differential	Nm	50
BA35.31-P-1003-02B	Breather, rear axle differential	Nm	30
BA35.31-P-1005-02B	Bolt, heat sink to end cover	Nm	37

REAR AXLE DIFFERENTIAL

Number	Designation			Model 203.020/076/220/276	Model 209.320/420, Model 209.375/376/475/476 as of 24.4.04 Model 209.372/472	Model 209.377/477
BF35.31-P-1001-01K	Filling capacity	Rear axle center assembly	Liters	1.2	1.2	1.2
BF35.31-P-1001-01K	Filling capacity	Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	BB00.40-P-0235-07A	BB00.40-P-0235-61A

Fig 2: Identifying Assembly Attachment (140 589 01 62 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