Replace radial sealing ring at drive pinion gear (with rear axle differential installed) - AR35.31-P-0530T

Rear axle differential dia. 198

in MODEL 211.006,

211.054/056 up to 31.5.06,

211.065/082/087/092,

211.254/256 up to 31.5.06,

211.206/265/282/287/292/606

Rear axle differential dia. 210

in model

211.016/023/026/028,

211.070/076 up to 31.8.03,

211.216/223/226,

211.270 up to 31.8.03,

211.616

rear axle differential 210E

Fig 1: Locating Radial Sealing Ring

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

7.4.04	Value changed from 1.4 liters to 1.6 liters	Value changed in series 1001 for models 211	*BF35.31-P-1001-01L
7.4.04	Specification revised from 1.1 liters to 1.2 liters	Value changed in row 1002 for model 211	*BF35.31-P-1002-01L
8.4.04	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04 The oil filler screws and oil drain screws should always be replaced after being unscrewed. The new oil filler screws and drain screws as well as the tapped holes must be cleaned with a special cleaning spray and provided with a special sealing compound.	BT35.31-P-0015-01A
	The oil drain screw must always be replaced after being unscrewed from the rear axle center assembly. The new oil drain screw as well as the tapped hole must be cleaned with a special cleaning spray and the oil drain screw must be provided with a special sealing compound		AR35.31-P-0520-06I
	The oil filler screw should always be replaced after being unscrewed from the rear axle differential. The new oil filler screw as well as the tapped hole must be cleaned with a special cleaning spray and the oil filler screw provided with a special sealing compound	Only carry out oil level check at interior temperature.	AR35.31-P-0520-03I
13.7.04	Value changed from 1.2 Nm to 1.1 Nm	Value in row 1002 rear axle center assembly changed for models 211, 230	*BF35.31-P-1002-01L
23.9.04	Tighten the hexagon nut with collar on 198 mm dia. rear axle differential in stages until the total friction torque measured previously is attained, added	Step 10.1

	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
	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 AIRmatic		AH32.22-P-1000-02T
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
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 completely using STAR DIAGNOSIS	Vehicles with air springs on rear axle
	Notes on air suspension	Vehicles without AIRmatic	AH32.22-P-1000-01T
	Notes on AIRmatic	Vehicles with AIRmatic (semi-active air suspension), code 489	AH32.22-P-1000-02T
		Vehicles with AIRmatic (semi-active air suspension), code 489	AR32.22-P-1500-04T
		Vehicles without AIRmatic	AR32.22-P-1500-04TA
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system
		Installation: Carefully observe the official charging process for the air springs to prevent them from possible destruction:	*211589000900
		Fill air springs using STAR DIAGNOSIS in design level.	AR32.22-P-1500-03T
			*BA32.25-P-1008-04B
			*BA32.25-P-1009-04B
		Electronic inclinometer, refer to GOTIS http://gotis.aftersales.mercedes-benz.com
3	Raise vehicle with lifting platform		AR00.60-P-1000T
4	Detach rear propeller shaft (106) from flange on rear axle differential (50)	Apply color markings indicating the position of the propeller shaft relative to the rear axle differential and the propeller shaft center support bearing (106a) to ensure that the components are fitted at the correct ex-factory positions on reinstallation, otherwise drive line vibrations may occur. Flexible disk remains on propeller shaft.	AR41.10-P-0050-04I
			*BA41.10-P-1002-01A
5	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
6	Unscrew bolts from propeller shaft intermediate bearing (106a) and remove rear propeller shaft (106).		*BA41.40-P-1001-01A
		Installation: Assemble propeller shaft in correct position. Only tighten the bolts of the propeller shaft intermediate bearing after attaching the flexible coupling to the rear axle center assembly (50): ↓
		Connect sections of propeller shaft.	AR41.10-P-0050-05DA
	Long-life grease (NLGI grade 2)		BB00.40-P-0266-02A
7	Drain oil from rear axle differential (50)		AR35.31-P-0520-06I
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
			*BA35.31-P-1003-02A
Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04	BT35.31-P-0015-01A
8	Remove left and right rear axle shafts (37)	Model 211 except model 211.2 without AIRmatic, model 211.6 and model 211.076	AR35.30-P-0620T
		Type 211.076	AR35.30-P-0620TA
		Model 211.2 without AIRmatic and model 211.6 Installation: Replace circlips (37o) on inner splined profiles.	AR35.30-P-0620TB
	Measure
9	Measure and note total friction torque of drive pinion		AR35.31-P-0530-04I
			*100589025900
			*001589492100
		Wrench bit 41 mm hexagon 3/4 inch four-point
10.1	Unscrew hexagon collar nut (40)	Rear axle differential dia. 198 mm Do not remove the collar protection when slackening hexagon collar nut.
			*129589010700
		Wrench bit 41 mm hexagon 3/4 inch four-point For better control when loosening the hexagon collar nut, press shop-made bush into the commercially available socket wrench bit: ↓ Fabricate press-in bush for socket.	WF58.50-P-3531-02A
		Installation: Replace hexagon nut with collar and tighten in stages until the total friction torque measured previously is attained. Installation: Secure hexagon nut with collar on joint flange of drive pinion: ↓	AR35.31-P-0530-01B
		Fabricate caulker for securing hexagon nut with collar on joint flange.	WF58.50-P-3531-01A
10.2	Unscrew hexagon collar nut (40)	Rear axle center assembly Ø 210 mm Do not remove the collar protection when slackening hexagon collar nut.
			*129589010700
		Wrench bit 41 mm hexagon 3/4 inch four-point For better control when loosening the hexagon collar nut, press shop-made bush into the commercially available socket wrench bit: ↓ Fabricate press-in bush for socket.	WF58.50-P-3531-02A
		Installation: Replace hexagon nut with collar and tighten in stages until the specified minimum tightening torque is attained.
	*BA35.31-P-1001-01A
		If the specified minimum tightening torque is not attained: ↓ Replace rear axle center assembly.
		Model 211 except model 211.616	AR35.31-P-0520T
		Type 211.616	AR35.31-P-0520TB
		Installation: Secure hexagon nut with collar on joint flange of drive pinion: ↓	AR35.31-P-0530-01B
		Fabricate caulker for securing hexagon nut with collar on joint flange.	WF58.50-P-3531-01A
11	Detach joint flange (41) from rear axle center assembly (50)	If necessary use puller.
			*129589013300
12	Pry radial sealing ring (42) out of rear differential assembly (50) using a suitable tool	Installation: Replace radial sealing ring, coat sealing lip with universal hypoid gear oil and press into rear axle center assembly using drift.
			*140589131500
	Universal hypoid gear oils		BB00.40-P-0235-07A
13	Install in the reverse order
14	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
		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
15.1	Activate 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 "Initial startup after repair "/" Remove/install brake shoes". 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
	Risk of accident when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work	Before starting engine, actuate brake pedal several times until the pressure is built up and maintained in the brake system.	AS42.50-Z-0002-01A
15.2	Press the brake pedal several times until the brake pads contact the brake disks	Vehicles with Adaptive Brake (ABR) Firm resistance should be noticeable at the brake pedal.

STRUTS

Number	Designation		Model 211 Airmatic	Model 211.2/6
BA32.25-P-1008-04B	Nut, rear air spring at spring control arm	Nm	150	150
BA32.25-P-1009-04B	Air suspension pressure line at rear axle distributor	Nm	2	2

REAR AXLE DIFFERENTIAL GEAR SET

Number	Designation		Model 211 with rear axle differential dia. 210 mm
BA35.31-P-1001-01A	Collar nut, joint flange to drive pinion	Nm	115

REAR AXLE CENTER ASSEMBLY HOUSING

Number	Designation		Model 211
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

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

PROPELLER SHAFT INTERMEDIATE BEARING

Number	Designation			Model 211
BA41.40-P-1001-01A	Bolt, propeller shaft intermediate 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	-

REAR AXLE DIFFERENTIAL

Number	Designation			Model 211 except 211.077/277
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