Remove/install complete rear axle - AR35.10-P-0010TA

MODEL 211.2 except CODE (489) Airmatic (semi-active air suspension)

MODEL 211.6

Fig 1: Identifying Complete Rear Axle Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

19.6.08

Value changed: Brake line to brake hose

*BA42.10-P-1001-04A

	Remove/install
	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
	Risk of injury caused by body parts being jammed or crushed. Risk of injury to skin and eyes caused by brake fluid spraying out at high pressure when working on the SBC brake system	Deactivate SBC brake system using STAR DIAGNOSIS.	AS42.46-Z-0001-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Caution, important note: The threads in the frame floor assembly must be recut and blown out, as any adhesive residue in a thread will prevent the bolt's necessary preload force from being achieved, despite having reached the specified torque and specified angle of rotation. If this is not observed, then the faulty bolt preload force will cause bending forces to act on the bolt, which could ultimately lead to bolt fracture.
	While working on the rear axle, care must be taken to ensure that the surface of aluminum components do not get any scratches, cracks and notches. Otherwise the service life of the parts will be affected
	Only tighten nuts and bolts of chassis components when vehicle is in a ready-to-drive condition.
1	Deactivate SBC brake system using STAR DIAGNOSIS.	Vehicles with Sensotronic Brake Control (SBC) The following steps should be run through in STAR DIAGNOSIS: Select menu item "SBC Sensotronic Brake Control "/" Deactivate 'SBC' system". Then process all the individual steps from top to bottom.
	Connect STAR DIAGNOSIS and read out fault memory	AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system
2	Empty air springs (6i) completely using STAR DIAGNOSIS		AR32.22-P-1500-04TA
	Notes on air suspension		AH32.22-P-1000-01T
			*211589000900
		Installation: The filling process of the air springs should be observed otherwise they will be irreparably damaged: Charge air springs using STAR DIAGNOSIS in design level.	AR32.22-P-1500-03TA
			*BA32.25-P-1008-04B
			*BA32.25-P-1009-04B
		Transmission jack, refer to GOTIS http://gotis.aftersales.mercedes-benz.com Electronic inclinometer, refer to GOTIS http://gotis.aftersales.mercedes-benz.com
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system
3.1	Remove rear muffler	Model 211.206/606/208/608	AR49.10-P-4951T
		Model 211.220/222/284/289/620	AR49.10-P-4951TI
3.2	Remove exhaust system from flange connection back	Model 211.216/616	AR49.10-P-7280T
3.3	Detach complete exhaust system	Model 211.261/265/280/282	AR49.10-P-7000TB
		Model 211.241/242	AR49.10-P-7000TK
		Model 211.254/256/287/292	AR49.10-P-7000TS
3.4	Remove exhaust system from pipe connection	Model 211.223/226	AR49.10-P-7281T
4	Remove rear section components on underfloor paneling		AR61.30-P-1001T
5	Unhook brake cables from automatic slack adjuster of parking brake		AR42.20-P-0525T
6	Detach propeller shaft (106) from flange on rear axle center assembly (50)	Flex disk remains on propeller shaft.	AR41.10-P-0050-04I
			*BA41.10-P-1002-01A
7	Detach fitting sleeves of flexible coupling on flange of rear axle center assembly (50)	If the fitted sleeves are jammed: ↓	AR41.10-P-0050-09DA
		Produce drift for detaching the fitting sleeves in the flexible coupling.	WF58.50-P-4110-01A
8	Remove bolts from propeller shaft intermediate bearing (106a) and remove rear part of propeller shaft (106)	Apply color markings indicating the position of the propeller shaft relative to the rear axle differential (50) and the propeller shaft center support bearing to ensure that the components are fitted at the correct ex-factory positions on reinstallation, otherwise drive line vibrations may occur. Installation: Assemble propeller shaft in correct position. Do not tighten the bolts of the propeller shaft center support bearing until you have secured the flexible coupling to the rear axle differential (50).	AR41.10-P-0050-05DA
			*BA41.40-P-1001-01A
	Long-life grease (NLGI grade 2)		BB00.40-P-0266-02A
9	Remove rear wheels
	Remove/install wheels		AP40.10-P-4050Z
10.1	Remove left and right rear brake calipers	For repair work on the tank or rear axle. Floating caliper	AR42.10-P-0080R
		Fixed caliper	AR42.10-P-0080RA
	Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.	Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.	AS42.50-Z-0001-01A
10.2	Detach left and right rear brake hose (51) from the brake lines	For bodywork or replacement of rear axle assembly.	AR42.10-P-0013T
		Seal off line connections immediately with plugs. The brake fluid expansion reservoir must not be allowed to run completely empty.
			*000589750300
			*129589009100
		When releasing or fastening the brake line on the brake hose make sure that its bracket is not twisted. Use an open-end wrench as a countersupport on the sides of the brake hose fitting. Installation: The brake hoses must not be twisted after being tightened (danger of cracking).
			*BA42.10-P-1001-04A
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on installing brake hoses		AH42.10-P-9406-01A
11	Detach left rear RPM sensor (L6/3) and right rear RPM sensor (L6/4) from the wheel carriers	Unclip electrical feed lines of RPM sensors from all retaining clamps and tie RPM sensors to one side.
			*BA42.30-P-1001-02A
12	Disconnect electrical connector from right rear brake pad contact sensor (S10/4)
13	Detach electrical feed line (1) of right rear brake pad contact sensor (S10/4)	Unclip electrical feed line from retaining clamps and tie to one side.	*BA42.10-P-1002-12H
14	Pry left and right air spring (6i) off the frame floor using assembly lever	This destroys the clips on the air springs. Installation: Slide on the air springs, continuing until the new clips can be heard engaging in the frame floor. The air springs should be aligned and should not have kinks.
15	Detach left and right shock absorbers (6j) from spring control arms		*BA32.25-P-1002-03G
16	Drain fuel tank.	Vehicles with diesel engine	AR47.10-P-4001T
		Vehicles with gasoline engine	AR47.10-P-4001TB
17	Remove filler hose (17) of fuel tank
18	Install guard plates (01) to protect brake disk cover panels		AR42.00-P-0100-01A
			*220589013100
19	Lower rear axle.	Installation: Recut and blow out the threads in the frame floor assembly to ensure a perfect threaded connection.	AR35.10-P-0020-01T
		Use new bolts.
			*BA35.10-P-1001-01E
			*BA35.10-P-1002-01E
		Transmission jack, transmission platform refer to GOTIS http://gotis.aftersales.mercedes-benz.com
20	Replace retaining clips of air springs (6i)		AR32.22-P-1500-02TA
	Checking
21	Check rear axle for damage, replace damaged parts
22	Check condition of air springs		AR32.22-P-1500-05TA
23	Install in the reverse order
24	Check oil level in rear axle center assembly (50) and correct if necessary	Mixing of old universal hypoid gear oil and the new FE hypoid gear oil should be avoided due to the better fuel economy.	AR35.31-P-0520-03I
			*BF35.31-P-1001-01L
			*BF35.31-P-1002-01L
			*BF35.31-P-1003-01L
			*BF35.31-P-1004-01L
			*BF35.31-P-1006-01L
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
			*BA35.31-P-1002-02A
	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04	BT35.31-P-0015-01A
25.1	Bleed brake system with STAR DIAGNOSIS	Vehicles with Sensotronic Brake Control (SBC)	AR42.10-P-0012R
		The following steps should be run through in STAR DIAGNOSIS: Select menu item "initial startup after repair "/" after opening or exchanging one or more brake hoses". Then process all the individual steps from top to bottom. When performing the bleeding operation always observe the instructions in the document "Bleeding brake system using STAR DIAGNOSIS".
25.2	Bleed brake system	Vehicles with Adaptive Brake (ABR)	AR42.10-P-0010T
26	Perform wheel alignment check		AR40.20-P-0200T

PROPELLER SHAFT

Number	Designation			Model 211
BA41.10-P-1002-01A	Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential.	M10	Nm	40
		M12	Nm	60

REAR AXLE BRAKE CALIPER

Number	Designation		Model 211 except model 211.076/077/276/277	Model 211.076/077/276/277
BA42.10-P-1002-12H	Bolt, brake pad contact sensor to brake caliper	Nm	8	8

PROPELLER SHAFT CENTER SUPPORT BEARING

Number	Designation			Model 211
BA41.40-P-1001-01A	Bolt, propeller shaft center support bearing to frame floor assembly	Self-tapping screw	Nm	25
		Bolt with washer	Nm	-
		Bolt with collar and self-centering tip	Nm	-
		Bolt with collar and without self-centering tip	Nm	-

BRAKE LINES, BRAKE HOSES

Number	Designation		Model 211 with SBC	Model 211 with ABR [Adaptive Brake]
BA42.10-P-1001-04A	Brake pipe to brake hose	Nm	18	18

REAR AXLE RPM SENSOR

Number	Designation		Model 211
BA42.30-P-1001-02A	Self-locking bolt of rear axle RPM sensor to wheel carrier	Nm	8

REAR AXLE CARRIER

Number	Designation			Model 211
BA35.10-P-1001-01E	Self-locking bolt, front rear axle carrier rubber bushing to frame floor	Stage 1	Nm	90
		Stage 2	∠°	60
BA35.10-P-1002-01E	Self-locking bolt, rear axle carrier rear rubber bushing to frame floor	Stage 1	Nm	90
		Stage 2	∠°	60

REAR AXLE SHOCK ABSORBER

Number	Designation				Model 211.2/6
BA32.25-P-1002-03G	Self-locking nut to spring control arm shock absorber	M10	Stage 1	Nm	50
			Stage 2	∠°	90

DIFFERENTIAL HOUSING

Number	Designation		Model 211
BA35.31-P-1002-02A	Oil filler screw, differential	Nm	50

SUSPENSION STRUTS

Number	Designation		Model 211.2/6
BA32.25-P-1008-04B	Nut, rear air spring at spring control arm	Nm	150
BA32.25-P-1009-04B	Air suspension pressure line at rear axle distributor	Nm	2

DIFFERENTIAL

Number	Designation			Model 211 except 211.077/277	Model 211.077/277, model 230.470/472/474/479
BF35.31-P-1001-01L	Filling capacity	210 mm dia. rear axle differential in rear axle differential 210E	Liters	1,6	-
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	-
BF35.31-P-1002-01L	Filling capacity	Rear axle differential dia. 198 mm	Liters	1,1	-
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	-
BF35.31-P-1003-01L	Filling capacity	Differential Ø 187 mm	Liters	1.0	-
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	-
BF35.31-P-1004-01L	Filling capacity	Differential Ø 215 mm	Liters	1,2	1,2
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	BB00.40-P-0235-61A
BF35.31-P-1006-01L	Filling capacity	200 mm dia. rear axle differential in rear axle differential 200FE	Liters	1,1	-
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	-

Fig 2: Identifying Guard Plate (220 589 01 31 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Wrench Socket (211 589 00 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Box Wrench Bit (000 589 75 03 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
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