Boot cap on joint ring removal and installation - AR35.30-P-0661-01P

REAR AXLE SHAFT, PLUGGED IN SHAFTS

Number	Designation			Model 170, 171, 172, 203, 204, 207, 208, 209, 211, 212, 215, 216, 218, 219, 220, 221, 230
BF35.30-P-1001-01G	Filling capacity for joint housing	Ø95	g	100
		Ø102	g	120
		Ø106	g	130
		Ø112	g	140
		Ø116	g	150

Remove boot cap

Using protective jaw pads, clamp rear halfshaft into vice.
Using a hand coping saw, saw cup seal (37i) radially in the groove on the press-in edge so that a notch arises.
When sawing make sure that the joint ring (37c) is not damaged.

Fig 1: Sawing Cup Seal
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use a screwdriver to lift the notched area.

Fig 2: Lifting Notched Area
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Starting at the raised end, use suitable pliers to rotate the cap seal (37i) until it is possible to lift the cap seal (37i) off the joint ring.
When rotating on the boot cap (37i) avoid allowing the rear halfshaft to drop out of the joint ring before the relative alignment positions of the components have been marked.
Remove hose clamps.
Pull boot with boot cap (37i) off joint ring and slide down rear halfshaft.
If both boots are to be replaced, the boot opposite can be slid over the rear-axle shaft.

Fig 3: Lifting Cap Seal Off Joint Ring
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install boot cap.
Replace O-ring on joint ring (37c).
Coat O-ring with spirit to make installation of the cup seal (37i) easier.

Do not grease or oil the O-ring, as this might cause the cap seal (37i) to turn on the joint ring (37c).
Mount cup seal (37i) with hose clamp and slide all the way onto the joint ring (37c). If necessary, drive fully home by tapping gently with a plastic mallet.
Slide on cup seal (37i) carefully otherwise the O-ring will be damaged.

Fig 4: Mounting Cup Seal With Hose Clamp
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
By four blows on the circumference, offset by 90° respectively, fix cup seal (37i) in place in the circumferential groove of the joint ring (37c).
Apply even blows using a suitable hammer to drive the cap seal into the groove extending along the periphery of the joint ring.
Check the cup seal is correctly seated.

Fig 5: Applying Blows To Drive Cap Seal Into Groove
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Through positioning a drift (Ø 4 mm) and applying uniform blows with the hammer, reposition the cup seal into the groove.

Fig 6: Repositioning Cup Seal Into Groove
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measure size of joint housing.
The quantity of grease required depends on the size of the joint housing. Using a vernier caliper determine diameter "A" on the outside of ball joint and diameter "B" on the inside of the ball joint.

For measuring points, see arrows.

For quantity of grease, see Table.

Fig 7: Measuring Size Of Joint Housing
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fill joint with new grease .
Slide boot (37l) onto cup seal (37i).
Ensure that the ridge (arrow) on the boot (37l) is resting between the ridges on the boot cap (37i).

After the boot (37l) is slid on, no grooves on the rear halfshaft should be visible at the end with the smaller diameter, this indicates that the ridge (37l) on the boot is in the first groove.

Fig 8: Confirming Ridge On Boot Is In First Groove
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install hose clamps (37k).
Ensure that dimension (a), measured on the inside, is not exceeded or fallen below.

Dimension:

a = 2 to 2.5 mm

Fig 9: Installing Hose Clamps
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.