Disassembling and assembling rear axle differential, adjusting gear set - AR35.31-P-0550T

Rear axle differential dia. 198 in model 211.004 with CODE (450) Taxi version

Rear axle differential dia. 198

in model 171.456, 211.006,

211.054/056 up to 31.5.06,

211.065/082/087/092/206,

211.254/256 up to 31.5.06,

211.265/282/287/292/606,

219.356 up to 31.5.06,

230.467

Fig 1: Identifying Rear Axle Differential Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
1	Raise vehicle with vehicle lift
2	Drain oil from rear axle differential (50)	Model 171	AR35.31-P-0520-06V
			*BA35.31-P-1003-02C
		Model 211, 230	AR35.31-P-0520-06I
			*BA35.31-P-1003-02A
		Model 219	AR35.31-P-0520-06TX
			*BA35.31-P-1003-02D
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
	Oil filler/drain screw on rear axle differential modified	Model 171, 211, 230: Phased in as of 19.01.04	BT35.31-P-0015-01A
3	Remove rear axle differential (50)	Model 171	AR35.31-P-0520V
		Model 211.0, model 211.2 with code (489) Airmatic (semi-active air suspension), model 211.004 with taxi version, code 450	AR35.31-P-0520T
		Model 211.2 without AIRmatic, model 211.6	AR35.31-P-0520TB
		Model 230	AR35.31-P-0520R
		Model 219	AR35.31-P-0520TX
	Disassemble
4	Clamp rear axle differential (50) in assembly stand.		AR35.31-P-0540-06TA
			*129589003100
			*140589406300
			*220589016300
5	Remove end cover (54)
6	Pry off left and right radial sealing ring (32a)		AR35.31-P-0540-05T
7	Remove left circlip (29) from rear axle housing using spreader.	Mark circlip (29).	AR35.31-P-0550-01T
		Rear axle housing expansion (spread dimension) for circlip removal	*BE35.31-P-1001-04F
			*140589053100
			*126589082100
		Pliers for circlip, inner
8	Remove right circlip (29) from rear axle housing.	Mark circlip (29). Pliers for circlip, inner
9	Remove both tapered roller bearing outer races (11a) out of rear axle housing	Mark tapered roller bearing outer races (11a).	AR35.31-P-0550-02T
			*116589186100
10	Take differential (13) out of rear axle housing		AR35.31-P-0550-03T
11	Detach both tapered roller bearing inner races (11b) from differential (13)	Mark tapered roller bearing inner races (11b).	AR35.31-P-0550-04T
			*123589083300
12	Loosen and remove retaining bolts (13a) from crown wheel (47a)	Mark position of ring gear (47a) in relation to differential (13).
13	Carefully press off crown wheel (47a) from differential (13)
14	Release and unscrew hexagon collar nut (40) on joint flange (41)	For better control when loosening the hexagon collar nut (40), press a shop-made bushing into the commercially available socket wrench bit: ↓	AR35.31-P-0550-05T
		Pressing bush for wrench socket	WF58.50-P-3531-02A
			*129589010700
		Wrench bit 41 mm hexagon 3/4 inch four-point
15	Detach joint flange (41).	If necessary mark joint flange (41) relative to drive pinion (47).	AR35.31-P-0550-06T
			*129589013300
16	Push drive pinion (47) out of rear axle housing		AR35.31-P-0550-07T
			*000589653300
17	Using a suitable screwdriver press radial sealing ring (42) out of rear axle case		AR35.31-P-0550-08T
18	Remove tapered roller bearing inner race (43d)
19	Remove tapered roller bearing outer races (43e, 46b) from rear axle housing		AR35.31-P-0550-09T
			*140589104300
20	Remove shim (45)
21	Remove spacer sleeve (44) with thrust plates (48) from drive pinion (47)
22	Pull tapered roller bearing inner race (46a) from drive pinion (47)		AR35.31-P-0550-10T
			*001589503300
			*000589633400
			*000589023400
			*140589000100
	Checking
23	Check all parts for reusability and replace if necessary	If the contact surfaces of the connecting and joint flanges show signs of galling due to the radial seal, the flanges must be replaced.
	Assembly, adjusting ring gear and pinion
24	Press tapered roller bearing inner race (46a) onto drive pinion (47)		AR35.31-P-0550-12T
	Assembly sleeve for tapered roller bearing inner race (46a)		WF58.50-P-3531-03A
25	Calculate shim (45) and installing in rear axle housing	Use data sheet.	AR35.31-P-0550-13T
		Data sheet, Adjusting rear axle gear set: Order No. B20.800.98.113.00C
			*363589022100
			*140589162300
			*140589142100
			*140589416300
			*000589381900
			*126589002100
26	Pull tapered roller bearing outer races (43e, 46b) into rear axle housing		AR35.31-P-0550-14T
			*140589014300
27	Install spacer sleeve (44) on drive pinion (47) with double-sided thrust plates (48)	Always replace spacer sleeve (44) and thrust plates (48).	AR35.31-P-0550-26T
28	Insert drive pinion (47) into rear axle housing.	Support drive pinion (47) with removal/installation device.	AR35.31-P-0550-15T
			*140589104300
29	Place tapered roller bearing inner race (43d) onto drive pinion gear (47) and press in together with radial sealing ring (42)	Replace radial sealing ring (42) and coat the lip with universal hypoid gear oil.	AR35.31-P-0550-16T
			*140589131500
			*000589653300
	Universal hypoid gear oils		BB00.40-P-0235-07A
30	Slide joint flange (41) onto drive pinion (47)	Observe any markings made. Coat the contact surface for the radial sealing ring (42) with universal hypoid gear oil.
	Universal hypoid gear oils		BB00.40-P-0235-07A
31	Screw on hexagon collar nut (40)	Install new collared hexagon nut (40). Wrench bit 41 mm hexagon 3/4 inch four-point
32	Adjusting friction torque of drive pinion bearing		AR35.31-P-0550-17T
		Friction torque of drive pinion bearing (new tapered roller bearings)	*BE35.31-P-1001-02G
			*129589010700
			*001589492100
			*100589025900
		Wrench bit 41 mm hexagon 3/4 inch four-point
33	Check adjustment dimension for drive pinion (47)		AR35.31-P-0550-18T
		Permissible deviation from the specified adjustment dimension on the end face of the drive pinion	*BE35.31-P-1001-03C
			*140589416300
			*000589381900
			*126589002100
34	Secure hexagon collar nut (40) at joint flange (41)		AR35.31-P-0550-29T
	Chisel for securing hexagon collar nut (40) on joint flange (41).		WF58.50-P-3531-01A
35	Dismantling and assembling differential (13)		AR35.31-P-0560T
36	Mount ring gear (47a) onto differential (13)	Pay attention to marks on ring gear (47a) and differential (13).	AR35.31-P-0550-19T
		Crown wheel heating temperature for installation	*BE35.31-P-1003-03C
			*BA35.31-P-1001-03F
			*BA35.31-P-1001-03G
			*124589072100
			*116589186100
37	Press tapered roller bearing inner races (11b) onto differential (13)		AR35.31-P-0550-20T
			*116589086100
			*116589186100
38	Install differential (13) in rear axle housing		AR35.31-P-0550-03T
39	Insert right tapered roller bearing outer race (11a) in rear axle housing		AR35.31-P-0550-21T
			*116589186100
40	Install right circlip (29) in rear axle housing.	Install the circlip (29) removed and marked previously in order to achieve a basic pretension of the rear axle housing. Pliers for circlip, inner	AR35.31-P-0550-22T
41	Insert left tapered roller bearing outer race (11a) into rear axle housing	Tapered roller bearing outer race (11a) must contact the tapered roller bearing inner race (11b).
			*116589186100
42	Remove both assembly mandrels from differential
43	Pretension (spread) rear axle housing using spreader.		AR35.31-P-0550-23T
		Rear axle housing expansion (spread dimension) when installing circlip	*BE35.31-P-1002-04F
			*140589053100
			*126589082100
44	Install left circlip (29) in rear axle housing.	Install the circlip (29) removed and marked previously in order to achieve a basic pretension of the rear axle housing. Pliers for circlip, inner	AR35.31-P-0550-27T
45	Release rear axle housing
46	Measure expanded dimension of rear axle housing		AR35.31-P-0550-24T
		Setting for rear axle housing expansion (spread dimension)	*BE35.31-P-1003-04F
			*140589053100
			*126589082100
47	Measure gear backlash between drive pinion (47) and ring gear (47a), correct if necessary.	The adjustment of the tapered roller bearings and gear set is OK, if the spread dimension (expansion) of the rear axle housing and gear backlash is within the range of specified values. This prevents damage to the teeth of the drive pinion gear (47) and the ring gear (47a).	AR35.31-P-0550-25T
		Gear backlash between crown wheel and pinion	*BE35.31-P-1002-03C
			*140589053100
			*140589082100
48		Remove spreader from rear axle housing
49	Press radial sealing rings (32a) into rear axle housing	Replace radial sealing rings (32a) and coat the lip with Universal hypoid gear oil.	AR35.31-P-0540-05T
			*140589101500
	Universal hypoid gear oils		BB00.40-P-0235-07A
50	Attach end cover (54)	End cover (54) with unmachined sealing surface.	AR35.31-P-0550-28T
			*BA35.31-P-1001-02C
			*BA35.31-P-1001-02A
			*BA35.31-P-1001-02D
		Loctite sealant 5970	*BR00.45-Z-1013-01A
			*112589002500
51	Replace rear axle breather (55) on end cover (54)		*BA35.31-P-1005-02C
			*BA35.31-P-1008-02A
			*BA35.31-P-1005-02D
			*BA35.31-P-1005-02A
52	Remove rear axle differential (50) from assembly stand
	Install
53	Install rear axle differential (50).	Model 171	AR35.31-P-0520V
		Model 211.0, 211.2 with code (489) Airmatic (semi-active air suspension), model 211.004 with taxi version, code 450	AR35.31-P-0520T
		Model 211.2 without AIRmatic and model 211.6	AR35.31-P-0520T
		Model 230	BAR35.31-P-0520R
		Model 219	AR35.31-P-0520TX
54	Pour oil into the rear axle differential (50)	Model 171	AR35.31-P-0520-03V
			*BF35.31-P-1001-01O
			*BA35.31-P-1002-02C
		Model 211, 230	AR35.31-P-0520-03I
			*BF35.31-P-1002-01L
			*BA35.31-P-1002-02A
		Model 219	AR35.31-P-0520-03TX
			*BF35.31-P-1004-01P
			*BA35.31-P-1002-02D
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
	Oil filler/drain screw on rear axle differential modified	Model 171, 211, 230: Phased in as of 19.01.04	BT35.31-P-0015-01A

TEST VALUES FOR FRICTION TORQUE OF REAR AXLE DIFFERENTIAL

Number	Designation		Model 171.456	Model 211.006/054/056/065/082/087/092/206/254/256/265/282/287/292/606, Model 211.004 with code 450
BE35.31-P-1001-02G	Friction torque of drive pinion bearing (new tapered roller bearings)	Nm	215...245	215...245

TEST VALUES FOR FRICTION TORQUE OF REAR AXLE DIFFERENTIAL

Number	Designation		Model 219.356	Model 230.467
BE35.31-P-1001-02G	Friction torque of drive pinion bearing (new tapered roller bearings)	Ncm	215...245	215...245

TEST VALUES FOR REAR AXLE DIFFERENTIAL

Number	Designation		Model 171.456	Model 211.006/054/056/065/082/087/092/206/254/256/265/282/287/292/606, Model 211.004 with code 450
BE35.31-P-1001-03C	Permissible deviation from the specified adjustment dimension on the end face of the drive pinion	mm	-0.02...+0.01	-0.02...+0.01
BE35.31-P-1002-03C	Gear backlash between crown wheel and pinion	mm	0.1...0.16	0.1...0.16
BE35.31-P-1003-03C	Crown wheel heating temperature for installation	°C	75...85	75...85

TEST VALUES FOR REAR AXLE DIFFERENTIAL

Number	Designation		Model 219.356	Model 230.467
BE35.31-P-1001-03C	Permissible deviation from the specified adjustment dimension on the end face of the drive pinion	mm	-0.02...+0.01	-0.02...+0.01
BE35.31-P-1002-03C	Gear backlash between crown wheel and pinion	mm	0.1...0.16	0.1...0.16
BE35.31-P-1003-03C	Crown wheel heating temperature for installation	°C	75...85	75...85

TEST VALUES FOR FRICTION TORQUE OF REAR AXLE DIFFERENTIAL

Number	Designation		Model 171.456	Model 211.006/054/056/065/082/087/092/206/254/256/265/282/287/292/606, Model 211.004 with code 450
BE35.31-P-1001-04F	Rear axle housing expansion (spread dimension) for circlip removal	mm	0.10...0.13	0.10...0.13
BE35.31-P-1002-04F	Rear axle housing expansion (spread dimension) when installing circlip	mm	0.3	0.3
BE35.31-P-1003-04F	Setting for rear axle housing expansion (spread dimension)	mm	0.11...0.17	0.11...0.17

TEST VALUES FOR FRICTION TORQUE OF REAR AXLE DIFFERENTIAL

Number	Designation		Model 219.356	Model 230.467
BE35.31-P-1001-04F	Rear axle housing expansion (spread dimension) for circlip removal	mm	0.10...0.13	0.10...0.13
BE35.31-P-1002-04F	Rear axle housing expansion (spread dimension) when installing circlip	mm	0.3	0.3
BE35.31-P-1003-04F	Setting for rear axle housing expansion (spread dimension)	mm	0.11...0.17	0.11...0.17

REAR AXLE CENTER ASSEMBLY HOUSING

Number	Designation				Model 211
BA35.31-P-1001-02A	Bolt, end cover to rear axle differential	Bolt+washer		Nm	-
		Flange bolt (TORX, internal serrations)	Stage 1	Nm	30
		Flange bolt (TORX, internal serrations)	Stage 2	∠°	45
BA35.31-P-1002-02A	Oil filler screw, rear axle differential			Nm	50
BA35.31-P-1003-02A	Oil drain screw for rear axle differential			Nm	50
BA35.31-P-1008-02A	Rear axle center assembly breather to end cover			Nm	25

REAR AXLE CENTER ASSEMBLY HOUSING

Number	Designation				Model 230 except code P99
BA35.31-P-1001-02A	Bolt, end cover to rear axle differential	Bolt+washer		Nm	-
		Flange bolt (TORX, internal serrations)	Stage 1	Nm	30
		Flange bolt (TORX, internal serrations)	Stage 2	∠°	45
BA35.31-P-1002-02A	Oil filler screw, rear axle differential			Nm	50
BA35.31-P-1003-02A	Oil drain screw for rear axle differential			Nm	50
BA35.31-P-1005-02A	Breather, rear axle differential			Nm	30

REAR AXLE CENTER ASSEMBLY HOUSING

Number	Designation				Model 171 except Model 171.473
BA35.31-P-1001-02C	Bolt, end cover to rear axle differential	Bolt+washer		Nm	-
BA35.31-P-1001-02C	Bolt, end cover to rear axle differential	Flange bolt (TORX, internal serrations)	Stage 1	Nm	30
		Flange bolt (TORX, internal serrations)	Stage 2	∠°	45
BA35.31-P-1002-02C	Oil filler screw, rear axle differential			Nm	50
BA35.31-P-1003-02C	Oil drain screw for rear axle differential			Nm	50
BA35.31-P-1005-02C	Breather, rear axle differential			Nm	25

REAR AXLE CENTER ASSEMBLY HOUSING

Number	Designation			Model 219
BA35.31-P-1001-02D	Bolt, end cover to rear axle differential	Stage 1	Nm	30
		Stage 2	∠°	45
BA35.31-P-1002-02D	Oil filler screw, rear axle differential		Nm	50
BA35.31-P-1003-02D	Oil drain screw for rear axle differential		Nm	50
BA35.31-P-1005-02D	Breather, rear axle differential		Nm	30

REAR AXLE CENTER ASSEMBLY CROWN WHEEL

Number	Designation		Model 171.456	Model 211.006/054/056/065/082/087/092/206/254/256/265/282/287/292/606, Model 211.004 with code 450	Model 230.467
BA35.31-P-1001-03F	Retaining bolt, ring gear to differential case	Nm	85	85	85

REAR AXLE CENTER ASSEMBLY CROWN WHEEL

Number	Designation		Model 219.356
BA35.31-P-1001-03G	Retaining bolt, ring gear to differential case	Nm	140

REAR AXLE DIFFERENTIAL

Number	Designation			Model 211 except 211.077/277	Model 230 except 230.470/472/474/479
BF35.31-P-1002-01L	Filling capacity	Rear axle differential dia. 198 mm	Liters	1.1	1.1
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	BB00.40-P-0235-07A

REAR AXLE DIFFERENTIAL

Number	Designation				Model 171 except Model 171.473
BF35.31-P-1001-01O	Filling capacity	Rear axle center assembly	187 FE, 187 mm dia.	Liters	1.0
			dia. 198 mm	Liters	1.1
			200 FE, 200 mm dia.	Liters	1.1
			215 FE, 215 mm dia.	Liters	-
		Specifications for Operating Fluids		Sheet	BB00.40-P-0235-07A

REAR AXLE DIFFERENTIAL

Number	Designation			Model 219 except 219.376/377
BF35.31-P-1004-01P	Filling capacity	Rear axle differential dia. 198 mm	Liters	1.1
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A

Fig 2: Identifying Assembly Stand (129 589 00 31 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Supports (140 589 40 63 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Drift (140 589 13 15 00)

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Fig 5: Identifying Drift (140 589 10 15 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Spreader (140 589 05 31 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Identifying Contact Arm (126 589 08 21 00)

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Fig 8: Identifying Spring Compressor (116 589 18 61 00)

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Fig 9: Identifying Puller (123 589 08 33 00)

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Fig 10: Identifying Pin Wrench (129 589 01 07 00)

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Fig 11: Identifying Puller (129 589 01 33 00)

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Fig 12: Identifying Puller (000 589 65 33 00)

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Fig 13: Identifying Removal And Installation Tool (140 589 10 43 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 14: Identifying Puller (001 589 50 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 15: Identifying Extension (000 589 63 34 00)

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Fig 16: Identifying Collet Chuck (000 589 02 34 00)

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Fig 17: Identifying Open End Wrench (140 589 00 01 00)

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Fig 18: Identifying Dial Indicator Holder (363 589 02 21 00)

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Fig 19: Identifying Measuring Plate (140 589 16 23 00)

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Fig 20: Identifying Measuring Device (140 589 14 21 00)

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Fig 21: Identifying Intermediate Rings (140 589 41 63 00)

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Fig 22: Identifying Dial Indicator (000 589 38 19 00)

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Fig 23: Identifying Measuring Device (126 589 00 21 00)

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Fig 24: Identifying Installer (140 589 01 43 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 25: Identifying Tooth Backlash Gauge (140 589 08 21 00)

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Fig 26: Identifying Torque Meter (001 589 49 21 00)

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Fig 27: Identifying Connecting Piece (100 589 02 59 00)

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Fig 28: Identifying Spring Compressor (116 589 08 61 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 29: Identifying Remote Thermometer (124 589 07 21 00)

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Fig 30: Identifying Supports (220 589 01 63 00)

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Fig 31: Identifying Squeeze Gun (112 589 00 25 00)

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REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Loctite sealant 5970	A 003 989 98 20
BR00.45-Z-1061-01A	Sealant, Omnifit 100H (50 g)	A 002 989 23 71
BR00.45-Z-1046-04A	Cleaning spray, Loctite 7063 (150ml)	A 001 986 71 71 10