Remove/install rear axle shaft - AR35.30-P-0620P

MODEL 203.004 /204 except CODE (450) Taxi version Rear axle differential 185

MODEL 203.035 /045 /061 /235 /245 /261 /735 /745 /747 Rear axle differential 185

MODEL 203.007 /081 /084 /087 /092 /207 /281 /284 /287 /292 /707, 209.341 /342 /343 /361 /441 /442 /461 Rear axle differential 187

MODEL 209.375 /376 /475 /476 up to 23.4.04 Rear axle differential 210E

MODEL 203.008 /064 /208 /264 /708 /764, 209.365 /465 Rear axle differential 198

MODEL 203.007 /207 with CODE (450) Taxi version Rear axle differential 198

MODEL 203.008 /208 /708, 209.308 Rear axle differential 200

MODEL 203.007 /207 with CODE (450) Taxi version Rear axle differential 200

Fig 1: Identifying Rear Axle Shaft Remove/Install Components - Shows Left Side Of Rear Axle

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
	Notes on self-locking nuts and bolts	All models	AH00.00-N-0001-01A
1	Lift/jack up vehicle		AR00.60-P-1000P
2	Remove twelve-point collar nut (40) from rear axle shaft (37)	To prevent wheel bearing damage the vehicle must not be moved on its wheels any more once the twelve-point collar nut (40) is loosened.	AR35.30-P-0115-01A
		Installation: Replace twelve-point collar nut (40).
			*BA35.30-P-1001-01A
		Torque wrench	Fig 6
3	Remove each wheel
	Remove/install wheels, rotate if necessary		AP40.10-P-4050Z
4	Remove fixed brake caliper (111) from the rear axle	Do not disconnect brake hose; tie up fixed brake caliper (111) to body.
			*BA42.10-P-1001-01A
		Torque wrench	Fig 8
5	Remove stabilizer bar link rod (6k)		*BA32.20-P-1001-04C
			*BA32.20-P-1005-04C
		Torque wrench	Fig 8
6	Remove left rear rpm sensor (L6/3) or right rear rpm sensor (L6/4) from wheel carrier (7)		*BA42.30-P-1001-02A
		Torque wrench	Fig 7
7	Remove torque strut (3) from wheel carrier (7)	Installation: The rear axle shaft (37) must be horizontal (suspension compressed) when the torque strut (3) is tightened, to ensure that the axle geometry is not influenced.
			*BA35.20-P-1002-03A
		Torque wrench	Fig 8
8	Detach camber strut (2) from wheel carrier (7).	Installation: The rear axle shaft (37) must be horizontal (suspension compressed) when the camber strut (2) is tightened, to ensure that the axle geometry is not influenced.
			*BA35.20-P-1002-02A
		Torque wrench	Fig 8
9	Detach tie rod (4) from wheel carrier (7)	Installation: The rear axle shaft (37) must be horizontal (suspension compressed) when the tie rod (4) is tightened, to ensure that the axle geometry is not influenced.
			*BA35.20-P-1002-04A
		Puller	Figure
		Thrust piece M10x1.5	Figure
		Torque wrench	Fig 8
10	Remove thrust arm (5) from wheel carrier (7)	Installation: The rear axle shaft (37) must be horizontal (suspension compressed) when the thrust arm (5) is tightened, to ensure that the axle geometry is not influenced.
			*BA35.20-P-1002-05A
		Torque wrench	Fig 8
11	Fold wheel carrier (7) outwards and simultaneously press the rear axle shaft (37) out of the rear axle shaft flange	Do not overstretch the brake cable (arrow) to avoid any damage. Do not damage the rubber boots of the rear axle shaft (37) and pulse ring for the left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4), otherwise the electronic stability program (ESP) will not function correctly. Fold back wheel carrier (7) and tie up securely.	AR35.30-P-0115-03B
		Extraction and insertion tool	Figure
		Bracket	Figure
12	Pull rear axle shaft (37) out of rear axle differential.	Model 203.007 /207 /707 with rear axle differential diameter 187, Model 203.008 /208 /708 with rear axle differential diameter 198, Model 203.007 /207 with rear axle differential diameter 198 with taxi version, code 450, Model 203.007 /207 with rear axle differential diameter 200 with taxi version, code 450, Model 203.008 /208 /708, 209.308 with rear axle differential diameter 200	AR35.30-P-0620-02PA
		Model 203.004 /204 with rear axle differential diameter 185, except Taxi version, code 450, Model 203.035 /045 /061 /235 /245 /261 /735 /745 /747 with rear axle differential diameter 185, Model 203.081/084/281/284, with rear axle differential diameter 187, Model 203.087/092/287/292, with rear axle differential diameter 187, Model 209.341 /342 /361 /441 /442 /461 with rear axle differential diameter 187, Model 209.375 /376 /475 /476 with rear axle differential diameter 210E, Model 209.365 /465 with rear axle differential diameter 198 Model 203.007 /207 with rear axle differential diameter 187 with Taxi version, code 450 Do not damage radial sealing ring in rear axle differential in order to avoid leaks.	AR35.30-P-0620-02P
	Checking
13	Check condition of radial sealing ring in rear axle differential, replace if necessary	If the radial sealing ring exhibits damage: ↓ Remove/install radial sealing ring of rear axle shaft (37) on rear axle housing
		Model 203 with rear axle center assembly diameter 185, Model 203.081 /084 /087 /092 /281 /284 /287 /292, 209.341 /342 /343 /361 /441 /442 /461 with rear axle differential diameter 187, Model 209.365 /465 with rear axle differential diameter 198, Model 209.316 with rear axle differential diameter 210E, 209.375 /376 /475 /476 to 23.4.04 with rear axle differential diameter 210E	AR35.31-P-0541P
		Model 203.008 /208 /708 with rear axle differential diameter 198, Model 203.007 /207 with rear axle differential diameter 198 with taxi version, code 450, Model 203.007 /207 with rear axle differential diameter 187 except taxi version, code 450, Model 203.008 /208 /708, 209.308 with rear axle differential diameter 200, Model 203.007 /207 with rear axle differential diameter 200 with Taxi version, code 450, Model 203.707 with rear axle differential diameter 187	AR35.31-P-0541DA
14	Install in the reverse order
15	Check oil level in rear axle differential and correct if necessary	In the interest of better fuel economy, avoid mixing old universal hypoid gear oil with new FE hypoid gear oil. New oil filling/oil drain screws should be used with rear axle differential diameter 185, 187, 198, 210 up to production date 18.1.04. ↓	AR35.31-P-0520-03I
	Oil filler/drain screw on rear axle differential modified	up to 18.1.04	BT35.31-P-0015-01A
	Universal hypoid gear oils (SAE 85 W-90)	Sheet 235.7	BB00.40-P-0235-07A
			*BA35.31-P-1001-02B
		Filling capacity of rear axle differential	*BF35.31-P-1001-01K
		Torque wrench	Fig 8
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
		Omnifit sealing compound 100H (50 g)	*BR00.45-Z-1061-01A

REAR AXLE STABILIZER BAR

Number	Designation		Model 203	Model 209
BA32.20-P-1001-04C	Nut, link rod to stabilizer bar	Nm	40	40
BA32.20-P-1005-04C	Bolt, link rod to wheel carrier	Nm	40	50

CAMBER STRUT

Number	Designation			Model 203	Model 209
BA35.20-P-1002-02A	Self-locking nut, camber strut to wheel carrier.	M10	Nm	-	-
BA35.20-P-1002-02A	Self-locking nut, camber strut to wheel carrier.	M12	Nm	70	70

TORQUE STRUT

Number	Designation			Model 203	Model 209
BA35.20-P-1002-03A	Self-locking nut, torque strut to wheel carrier	Stage 1	Nm	70	50
BA35.20-P-1002-03A	Self-locking nut, torque strut to wheel carrier	Stage 2	∠ °	-	45

TIE ROD

Number	Designation			Model 203	Model 209
BA35.20-P-1002-04A	Self-locking nut, tie rod to wheel carrier	yellow M10x1	Nm	-	-
		silver or blue M10x1	Nm	-	-
		silver or blue M10x1.5	Nm	30	30

TORQUE STRUT

Number	Designation			Model 203	Model 209
BA35.20-P-1002-05A	Self-locking nut, thrust arm to wheel carrier	M10	Nm	-	-
		M12	Nm	70	50
			∠ °	-	45

REAR AXLE SHAFT

Number	Designation			Model 203	Model 209
BA35.30-P-1001-01A	Collar nut, rear axle shaft to rear axle shaft flange	Stage 1	Nm	220	220
BA35.30-P-1001-01A	Collar nut, rear axle shaft to rear axle shaft flange	Stage 2	∠ °	-	-