Remove/install protective cap for input shaft on steering gear - AR46.20-P-0004P

MODEL 169, 171, 172, 203, 204, 207, 209, 211, 212, 218, 230, 245 rack-and-pinion steering removed

Shown on model 203, left-hand drive vehicle

Fig 1: Identifying Clip, Bellows And Inner Tie Rod With Axial Joint

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Steering Gear Housing And Stop Ring

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Model 169 up to 30.3.05, left-hand drive vehicle

Fig 3: Identifying Protective Cap And Marking

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Model 169, 245, right-hand drive vehicle

Fig 4: Identifying Protective Cap And Marking

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Model 169 as of 31.3.05, model 245, left-hand drive vehicle

Fig 5: Identifying Protective Cap And Marking

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 203, left-hand drive vehicle

Fig 6: Identifying Protective Cap And Markings

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 203, right-hand drive vehicle

Fig 7: Identifying Protective Cap And Markings

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 211, left-hand drive vehicle

Fig 8: Identifying Protective Cap And Markings

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 211, right-hand drive vehicle

Fig 9: Identifying Protective Cap And Markings

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Model 207, 212, 230,

Shown on model 230, left-hand drive vehicle

Fig 10: Identifying Protective Cap And Markings

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Model 218, left-hand drive vehicle

Fig 11: Identifying Protective Cap And Markings

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 230, right-hand drive vehicle

Fig 12: Identifying Protective Cap And Markings

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing
1	Mount the rack-and-pinion steering onto steering gear housing support	Make sure that the workplace is clean when carrying out the work described below and while performing repairs. Only the specified tools may be used. Before starting the repair work, remove any loose dirt from the steering gear without using cleaning agents.
1		Steering gear housing support	Fig 13
2	Detach clamps (1) from both boots (2)
3	Press clamps together on inner tie rods with axial joints (3) and slide boots (2) towards tie rod end
4	Detach left and right inner tie rod with axial joint (3)	Do not use force (hammer blows, excessive leverage). Otherwise the inner tie rods with axial joints (3) may be damaged.
		Open-end wrench (Model 171, 172, 203, 204.0/2, 207, 209, 211, 230)	Fig 14
		Plug in open-end wrench (Model 204.9, 212, 218)	Fig 16
		Open-end wrench bit (Model 169, 245)	Fig 15
5	Move steering rack to center position	Use depth gauge to determine center position. Balance out the gaps from the end of the steering rack to the stop ring (16) in the steer jacket (14) on both sides of the steering rack.
6	Detach protective cap (4)
	Install
7	Grease gap between input shaft and control head (arrow)	Except model 169, 245 Apply grease using fingers. Do not use any other aid.
7	Grease gap between input shaft and control head (arrow)	Renolit JP1619 special grease	*BR00.45-Z-1067-06A
8	Fit protective cap (4)	Marking (5) must line up exactly with marking (6). Otherwise the Electronic Stability Program (ESP(r)) may malfunction. Model 169, 245: There are various versions of the protective cap (4). The same version as the one fitted must always be reinstalled.
	Modified rack-and-pinion steering	Model 169 as of 31.3.05	BT46.20-P-0600-01AK
	Checking
9	Check center steering position on steering gear		AR46.20-P-3015P
10	Mount left and right inner tie rod with axial joint (3)	Do not use force (hammer blows, excessive leverage). Otherwise the inner tie rod with axial joint (3) may be damaged.
		Model 171, 172, 203, 209, 211, 230	*BA46.40-P-1003-01E
		Model 169, 245	*BA46.40-P-1003-01J
		Model 204, 207, 212, 218	*BA46.40-P-1003-01N
		Open-end wrench (Model 171, 172, 203, 204, 207, 209, 211, 230, except 204.9)	Fig 14
		Plug in open-end wrench (Model 204.9, 212, 218)	Fig 16
		Open-end wrench bit (Model 169, 245)	Fig 15
11	Slide boots (2) onto steering housing (14) and position	Model 169, 230, 245
11	Slide boots (2) onto steering housing (14) and position	Model 171, 172, 203, 204, 207, 209, 211, 212, 218	AR46.40-P-0400-02CW
12	Mount clamps (1) of both bellows (2)	Replace clamps (1). Note position of clamps (1). Model 169, 171, 203, 209, 211, 230, 245
12	Mount clamps (1) of both bellows (2)	Model 172, 204, 207, 212, 218	AR46.40-P-7200-01EW
13	Detach rack-and-pinion steering from steering gear housing support

TIE ROD

Number	Designation		Model 171	Model 172
BA46.40-P-1003-01E	Inner track rod with axial joint to rack-and-pinion joint	Nm	110	110

TIE ROD

Number	Designation		Model 203 except model 203.081/084/ 087/092/281/ 284/287/292	Model 203.081/084/ 087/092/281/ 284/287/292
BA46.40-P-1003-01E	Inner track rod with axial joint to rack-and-pinion joint	Nm	110	110

TIE ROD

Number	Designation		Model 209	Model 211 except 211.08/09/ 28/29	Model 211.08/09/ 28/29	Model 230
BA46.40-P-1003-01E	Inner track rod with axial joint to rack-and-pinion joint	Nm	110	110	110	110

TIE ROD

Number	Designation		Model 169	Model 245
BA46.40-P-1003-01J	Inner tie rod to rack-and-pinion steering	Nm	80	80

TIE ROD

Number	Designation		Model 204	Model 207	Model 212	Model 218
BA46.40-P-1003-01N	Inner tie rod to rack-and-pinion steering	Nm	110	110	110	110

Fig 13: Identifying Steering Gear Housing Support (221 589 01 31 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 14: Identifying Open End Wrench (201 589 00 01 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 15: Identifying Open-End Wrench Bit (169 589 00 01 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 16: Identifying Plug In Open-End Wrench (221 589 02 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1067-06A	Renolit JP1619 special grease	A 001 989 38 51 10