Remove/install differential - AR35.31-P-0520T

Rear axle differential dia. 187 in MODEL 211.004 /041 /042 /052 /061 /080 /083 /084 /089 /090 /283 /290

Rear axle differential dia. 198 in model 211.006, 211.054 /056 up to 31.5.06, 211.065 /082 /087 /092

Rear axle differential dia. 200 in model 211.007 /008, 211.054 /056 as of 1.6.06, 211.057

Rear axle differential dia. 210 in model 211.016 /023 /026 /028, 211.070 /076 /270 up to 31.8.03

Rear axle differential dia. 215 in MODEL 211.020 /022 /029 /072 /272 /276 /077 /277

Rear axle differential dia. 187 in MODEL 211.241 /242 /252 /261 /280 /284 /289 with CODE (489) Airmatic (semi-active air suspension)

Rear axle differential dia. 198 in model 211.206, 211.254 /256 up to 31.5.06, 211.265 /282 /287 /292 with CODE (489) Airmatic (semi-active air suspension)

Rear axle differential dia. 200 in model 211.208, 211.254 /256 as of 1.6.06, 211.257 with CODE (489) Airmatic (semi-active air suspension)

Rear axle differential dia. 210 in MODEL 211.216 /223 /226 with CODE (489) Airmatic (semi-active air suspension)

Rear axle differential dia. 215 in MODEL 211.220 /222 with CODE (489) Airmatic (semi-active air suspension)

Rear axle differential dia. 215 in MODELS 211.070 /076 /270 as of 1.9.03

Rear axle differential dia. 198 in model 211.004 with CODE (450) Taxi version

Fig 1: Identifying Differential Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 211 with Airmatic

MODIFICATION NOTES

11.8.06

Filling capacity, Specifications for Operating Fluids

Model 211.077/277, 230.472/474/479

*BF35.31-P-1004-01L

	Remove/install
	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 AIRMATIC (semi-active air suspension), code 489	AR32.22-P-1500-04T
		STAR DIAGNOSIS diagnosis system	Figure
		Installation: The filling process for the air springs must be observed, otherwise the air springs will be irreparably damaged.	AR32.22-P-1500-03T
			*BA32.25-P-1008-04B
		Electronic inclinometer, refer to GOTIS http://gotis.aftersales.mercedes-benz.com	*BA32.25-P-1009-04B
3	Secure vehicle on vehicle lift		AR00.60-P-0100T
4.1	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
4.2	Remove exhaust system from flange connection back	Model 211.016 / 216	AR49.10-P-7280T
4.2	Remove exhaust system from flange connection back	Model 211.028	AR49.10-P-7280TC
4.3	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 211.052 /054 /056 /057 /072 /087 /090 / 092 /252 /254 /256 /257 /272 /287 /290 /292	AR49.10-P-7000TS
4.4	Remove exhaust system from pipe connection	Model 211.023 /026 /223 /226	AR49.10-P-7281T
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 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.
		Installation: Attach the propeller shaft.	AR41.10-P-0050-04I
			*BA41.10-P-1002-01A
7	Undo 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)	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)	Sheet 266.2	BB00.40-P-0266-02A
9	Remove right rear axle shaft (37)		AR35.30-P-0620T
10	Remove bolts (41j) and remove left and right additional volume reservoirs (41p) from front center assembly mounting (51)	Vehicles with AIRMATIC (semi-active air suspension), code 489
10			*BA32.22-P-1009-03A
11	Support differential (50) with transmission jack and transmission plate and lash down securely	Transmission platform, refer to GOTIS http://gotis.aftersales.mercedes-benz.com Transmission jack, refer to GOTIS http://gotis.aftersales.mercedes-benz.com
12.1	Remove the screw (64b) for the rear center assembly mounting on the rear axle carrier	Model 211 except model 211.276 /077 /277 and model 211.070 /270 /076 as of 1.9.03
			*BA35.10-P-1004-01E
			Figure
12.2	Remove both bolts of the rear differential mount on the rear axle carrier	Model 211.276 /077 /277 and model 211.070 /270 /076 as of 1.9.03
			*BA35.10-P-1004-01E
			Figure
13	Remove left and right bolts (51a) of front center assembly mounting (51)	Installation: Ensure that the shims (51b) are correctly positioned. The triangular bulges must point upwards.
13			*BA35.10-P-1006-01E
14	Lower the differential (50) slightly
15	Lift out the left rear axle shaft (37) from the rear axle center assembly (50)	Do not fasten an assembly lever to the protection ring (37a). Support assembly lever, with open end wrench for example, at rear axle differential. Tie up the left rear axle shaft. Installation: Install new retaining ring (37o) on inner splined profile.
16	Lower differential (50) further
17	Remove bolts (51c) and remove front center assembly mounting (51)		*BA35.10-P-1004-01E
18	Install in the reverse order
19	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
			*BA35.31-P-1002-02A
			*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
	Oil filler/drain screw on rear axle differential modified		BT35.31-P-0015-01A
20.1	Activate SBC brake system using STAR DIAGNOSIS	Vehicles with Sensotronic Brake Control (SBC) The following steps should be run through in STAR DIAGNOSIS: Select "Initial startup after repair"/"Remove/install brake pads" menu item. 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	Press the brake pedal several times until the brake pads contact the brake disks 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
20.2	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.
21	Perform wheel alignment check		AR40.20-P-0200T

DIFFERENTIAL HOUSING

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

AIR SUSPENSION

Number	Designation		Model 211 with code 489 (Airmatic)
BA32.22-P-1009-03A	Bolt, additional volume reservoir to front center assembly mount	Nm	20

REAR AXLE CARRIER

Number	Designation			Model 211
BA35.10-P-1004-01E	Self-safety bolt, rear axle center assembly at rear at rear axle crossmember	M14 rear	Nm	80
			∠°	60
		M10 front	Nm	65
BA35.10-P-1006-01E	Self-locking bolt, front crossmember to rear axle carrier	Stage 1	Nm	50
BA35.10-P-1006-01E	Self-locking bolt, front crossmember to rear axle carrier	Stage 2	∠°	90

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 Wrench Socket (211 589 00 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Box Wrench Bit (211 589 01 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