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

MODEL 211.0

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

Fig 1: Identifying Complete Rear Axle Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 211 with Airmatic

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 pretension force will cause transverse forces to be applied to the bolt, which may cause the bolt to 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	Vehicles with AIRMATIC (semi-active air suspension), code 489	AR32.22-P-1500-04T
	Notes on AIRmatic	Vehicles with AIRMATIC (semi-active air suspension), code 489	AH32.22-P-1000-02T
			Fig 3
	Fill the air spring in vehicle riding height position	Vehicles with AIRMATIC (semi-active air suspension), code 489	AR32.22-P-1500-03T Installation: The filling process for the air springs must be observed, otherwise the air springs will be irreparably damaged.
			*BA32.25-P-1008-04B
		Transmission jack, refer to GOTIS http://gotis.aftersales.mercedes-benz.com Electronic inclinometer (CM 09606), refer to GOTIS http://gotis.aftersales.mercedes-benz.com	*BA32.25-P-1009-04B
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system
3.1	Remove rear muffler	Model 211.004/ 006/ 206/ 007/ 008/ 208	AR49.10-P-4951T
		Model 211.020/ 220/ 022/ 222/ 084/ 089/ 284/ 289	AR49.10-P-4951TI
		Model 211.029	AR49.10-P-4951TJ
3.2	Remove exhaust system from flange connection back	Model 211.016 / 216	AR49.10-P-7280T
3.2	Remove exhaust system from flange connection back	Model 211.028	AR49.10-P-7280TC
3.3	Detach complete exhaust system	Model 211.061 /065 /070 /076 /077 /261 /265 /270 /276 /277 /080 /082 /083 /280 /282 /283	AR49.10-P-7000TB
		Model 211.041 /241 /042 /242	AR49.10-P-7000TK
		Model 211.054 /056 /072 /087 /090 /092 /254 /256 /272 /287 /290 /292	AR49.10-P-7000TS
3.4	Remove exhaust system from pipe connection	Model 211.023 /026 /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)	Apply color markings indicating the position of the propeller shaft relative to the transmission, 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. Flex disk remains on propeller shaft.	AR41.10-P-0050-04I
6			*BA41.10-P-1002-01A
7	Detach fitting sleeves of flexible coupling on flange of rear axle center assembly (50)		AR41.10-P-0050-09DA
	Drift for loosening fitting sleeves in flex disks.		WF58.50-P-4110-01A
8	Remove bolts from propeller shaft intermediate bearing (106a) and remove rear part of propeller shaft (106)	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)	Sheet 266.2	BB00.40-P-0266-02A
9	Remove rear wheels
	Remove/install wheels, rotate if necessary		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. Seal off line connections immediately with plugs. The brake fluid expansion reservoir must not be allowed to run completely empty.	AR42.10-P-0013T
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on installing brake hoses		AH42.10-P-9406-01A
		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.
			Fig 5
		Installation: The brake hoses must not be twisted after being tightened (danger of cracking).	Fig 4
			*BA42.10-P-1001-04A
11	Remove fender liners from rear fenders	Vehicles with AIRMATIC (semi-active air suspension), code 489	AR88.10-P-1400T
12	Disconnect electrical connectors of brake and chassis components at the rear axle	Vehicles with AIRMATIC (semi-active air suspension), code 489	AR32.22-P-1500-01TH
13	Detach left rear RPM sensor (L6/3) and right rear RPM sensor (L6/4) from the wheel carriers	Vehicles without AIRmatic Unclip electric feed lines of RPM sensor from all retaining clamps and tie up RPM sensor to one side.
13			*BA42.30-P-1001-02A
14	Disconnect electrical connector from right rear brake pad contact sensor (S10/4)	Vehicles without AIRmatic
15	Detach electrical feed line (1) of right rear brake pad contact sensor (S10/4)	Vehicles without AIRmatic Unclip electrical feed line from retaining clamps and tie up to one side.
15			*BA42.10-P-1002-12H
16.1	Use assembly lever to pry left and right air springs (6i) off the frame floor	Vehicles with AIRMATIC (semi-active air suspension), code 489 The retaining clips of the air springs are destroyed in the process. Installation: Slide on the air springs until the new retaining clips can be heard engaging in the frame floor. The air springs should be aligned and should not have kinks.
16.2	Remove left and right rear springs	Model 211.0 without AIRmatic
		Model 211.0 except 4MATIC	AR32.20-P-0230P
		Model 211.08 / 09	AR32.20-P-0230T
17	Remove damper (6j) at left and right from spring control arms	Vehicles with AIRMATIC (semi-active air suspension), code 489
17			*BA32.25-P-1002-03G
18	Drain fuel tank.	Vehicles with diesel engine except engine 629	AR47.10-P-4001T
		Engine 629	AR47.10-P-4001TJ
		Vehicles with gasoline engine	AR47.10-P-4001TB
19	Remove filler hose (17) of fuel tank
20	Install guard plates (01) to protect brake disk cover panels		AR42.00-P-0100-01A
20			Fig 2
21	Lower rear axle.	Installation: Recut and blow out the threads in the frame floor assembly to ensure a perfect threaded connection. Use new bolts.	AR35.10-P-0020-01T
			*BA35.10-P-1001-01E
		Transmission platform, refer to GOTIS http://gotis.aftersales.mercedes-benz.com Transmission jack, refer to GOTIS http://gotis.aftersales.mercedes-benz.com	*BA35.10-P-1002-01E
22	Replace retaining clips of air springs (6i)	Vehicles with AIRMATIC (semi-active air suspension), code 489	AR32.22-P-1500-02T
	Checking
23	Check rear axle for damage, replace damaged parts
24	Check condition of air springs (6i)	Vehicles with AIRMATIC (semi-active air suspension), code 489	AR32.22-P-1500-05T
25	Install in the reverse order
26	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
			*BA35.31-P-1002-02A
		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	Phased in as of 19.01.04	BT35.31-P-0015-01A
27.1	Bleed brake system with 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"/"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". STAR DIAGNOSIS diagnosis system	AR42.10-P-0012R
27.2	Bleed brake system	Vehicles with Adaptive Brake (ABR)	AR42.10-P-0010T
28	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
BA41.10-P-1002-01A		M12	Nm	60

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 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

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

REAR AXLE SHOCK ABSORBER

Number	Designation				Model 211.0 with code 489a AIRmatic	Model 211.2/6
BA32.25-P-1002-03G	Self-locking nut to spring control arm shock absorber	M10	Stage 1	Nm	50	50
BA32.25-P-1002-03G	Self-locking nut to spring control arm shock absorber	M10	Stage 2	∠°	90	90

DIFFERENTIAL HOUSING

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

SUSPENSION STRUTS

Number	Designation		Model 211 AIRMATIC
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	-
BF35.31-P-1001-01L	Filling capacity	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	-
BF35.31-P-1002-01L	Filling capacity	Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	-
BF35.31-P-1003-01L	Filling capacity	Differential Ø 187 mm	Liters	1.0	-
BF35.31-P-1003-01L	Filling capacity	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
BF35.31-P-1004-01L	Filling capacity	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	-
BF35.31-P-1006-01L	Filling capacity	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