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

MODEL 219.3

Shown on model 219 with AIRmatic

Fig 1: Identifying Complete Rear Axle Remove/Install Components - Shown On Model 219 With AIRmatic

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

19.6.08

Value changed: Union nut, brake line to brake hose

*BA42.10-P-1001-04I

	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
	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 the menu item "SBC-Sensotronic Brake Control"/"Initial startup after repair"/"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
2	Empty air springs (6i) completely using STAR DIAGNOSIS	Vehicles with AIRmatic (semi-active air suspension), code 489	AR32.22-P-1500-04TX
	Notes on AIRmatic		AH32.22-P-1000-02T
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		Observe the filling process of the air springs (6i) otherwise they will be destroyed.	AR32.22-P-1500-03TX
			*BA32.25-P-1006-04K
			*BA32.25-P-1007-04K
		Electronic inclinometer	Fig 3
3	Secure vehicle on the lifting platform		AR00.60-P-0100TX
4.1	Remove exhaust system at flange connection	Model 219.354/356/357/372	AR49.10-P-7280TX
4.1	Remove exhaust system at flange connection	Model 219.375/376/377	AR49.10-P-7280TY
4.2	Remove rear muffler	Model 219.322	AR49.10-P-4951TQ
5	Remove rear section components on underfloor paneling		AR61.30-P-1001TX
6	Detach propeller shaft (106) from rear axle differential (50)	The flexible coupling remains on the propeller shaft (106).
		Attach propeller shaft to rear axle differential (50).	AR41.10-P-0050-04TX
			*BA41.10-P-1002-01E
7	Remove fitting sleeves of flexible coupling from rear axle center assembly (50) on the flange		AR41.10-P-0050-09TX
	Drift for loosening fitting sleeves in flexible coupling.		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 (106) in correct order. Only tighten the bolts of the propeller shaft center support bearing (106a) after fastening the flexible coupling on the rear axle differential (50).	AR41.10-P-0050-05TX
			*BA41.40-P-1001-01B
	Long-life grease (NLGI grade 2)		Long-life grease (NLGI grade 2). See https://bevo.mercedes-benz.com/index.php?language_id=1
9	Unhook brake cables from automatic slack adjuster of parking brake		AR42.20-P-0525TX
10	Remove rear wheels
	Remove/install wheels, rotate if necessary		AP40.10-P-4050TX
11.1	Remove left and right rear brake calipers	For repair work on fuel tank or rear axle.	AR42.10-P-0080TX
	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
11.2	Detach left and right rear brake hose (51) from the brake lines	For bodywork or replacement of rear axle assembly.	AR42.10-P-0013TX
		The brake hoses (51) must not be twisted after tightening otherwise they may tear. Seal off line connections immediately with plugs. The brake fluid expansion reservoir must not be allowed to run completely empty. When loosening or tightening the brake line on the brake hose (51), take care not to twist its bracket. Counterhold open wrench on two flats of brake hose (51) using an open-end wrench.
			*BA42.10-P-1001-04I
			Fig 5
			Fig 4
12	Remove fender liners from rear fenders	Vehicles with AIRmatic (semi-active air suspension), code 489	AR88.10-P-1400TX
13	Disconnect electrical connectors of brake and chassis components at the rear axle	Vehicles with AIRmatic (semi-active air suspension), code 489	AR32.22-P-1500-01TX
14	Remove 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.
14			*BA42.30-P-1001-02A
15	Disconnect electrical connector from right rear brake pad contact sensor (S10/4)	Vehicles without AIRmatic
16	Detach electrical feed line (1) from right rear brake pad contact sensor (S10/4)	Vehicles without AIRmatic Unclip electrical feed line from retaining clamps and tie up to one side.
16			*BA42.10-P-1002-12B
17.1	Pry left and right air spring (6i) off the frame floor using assembly lever	Vehicles with AIRmatic (semi-active air suspension), code 489 In doing so the retaining clips for the air springs (6i) are destroyed. Slide on the air springs (6i), until the new clips can be heard engaging into the frame floor. The air springs (6i) must be aligned straight and must not be kinked.
17.2	Remove left and right rear springs	Vehicles without AIRmatic	AR32.20-P-0230TX
18	Detach left and right shock absorbers (6j) from spring control arms	Vehicles with AIRmatic (semi-active air suspension), code 489
18			*BA32.25-P-1002-03I
19	Drain fuel tank.	Vehicles with diesel engine	AR47.10-P-4001TQ
19	Drain fuel tank.	Vehicles with gasoline engine	AR47.10-P-4001TX
20	Remove filler hose (17) of fuel tank	Check filler hose (17) and clamps for damage.
21	Install guard plates (01) to protect brake disk cover panels		AR42.00-P-0100-01TX
21			Fig 2
22	Lower rear axle.	Do not damage filler hose (17). Kink filler hose (17) downwards when lowering the rear axle.	AR35.10-P-0020-01TX
			*BA35.10-P-1001-01J
			*BA35.10-P-1002-01J
		Recut and blow out the threads in the frame floor assembly to ensure a perfect threaded connection. Use new bolts.
23	Replace retaining clips of air springs (6i)	Vehicles with AIRmatic (semi-active air suspension), code 489	AR32.22-P-1500-02TX
	Checking
24	Check rear axle for damage, replace damaged parts
25	Check condition of air springs (6i)	Vehicles with AIRmatic (semi-active air suspension), code 489	AR32.22-P-1500-05TX
26	Install in the reverse order
27	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-0520-03TX
			*BA35.31-P-1002-02D
			*BF35.31-P-1003-01P
			*BF35.31-P-1004-01P
			*BF35.31-P-1005-01P
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
28.1	Bleed brake system with STAR DIAGNOSIS	Vehicles with Sensotronic Brake Control (SBC)	AR42.10-P-0012TX
28.1	Bleed brake system with STAR DIAGNOSIS	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".
28.2	Bleed brake system	Vehicles with Adaptive Brake (ABR)	AR42.10-P-0010T
29	Perform a wheel alignment check		AR40.20-P-0200TX

REAR AXLE RPM SENSOR

Number	Designation		Model 219
BA42.30-P-1001-02A	Self-locking bolt of rear axle rpm sensor to wheel carrier	Nm	8

PROPELLER SHAFT

Number	Designation			Model 219
BA41.10-P-1002-01E	Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential.	M12	Nm	60

PROPELLER SHAFT INTERMEDIATE BEARING

Number	Designation			Model 219
BA41.40-P-1001-01B	Bolt, propeller shaft intermediate bearing to frame floor assembly	Self-tapping screw	Nm	25

BRAKE LINES, BRAKE HOSES

Number	Designation		Model 219 with SBC	Model 219 with ABR
BA42.10-P-1001-04I	Union nut, brake line to brake hose	Nm	18	18

REAR AXLE BRAKE CALIPER

Number	Designation		Model 219
BA42.10-P-1002-12B	Bolt, brake pad contact sensor to brake caliper	Nm	8

REAR AXLE CARRIER

Number	Designation			Model 219
BA35.10-P-1001-01J	Self-locking bolt, front rear axle carrier rubber mount to frame floor	Stage 1	Nm	90
BA35.10-P-1001-01J		Stage 2	∠°	60
BA35.10-P-1002-01J	Self-locking bolt, rear axle carrier rear rubber mount to frame floor	Stage 1	Nm	90
BA35.10-P-1002-01J		Stage 2	∠°	60

REAR AXLE SHOCK ABSORBER

Number	Designation			Model 219 AIRmatic
BA32.25-P-1002-03I	Self-locking nut for attaching shock absorber to spring control arm	M10	Nm	55

REAR AXLE CENTER ASSEMBLY HOUSING

Number	Designation		Model 219
BA35.31-P-1002-02D	Oil filler screw, rear axle differential	Nm	50

SUSPENSION STRUTS

Number	Designation		Model 219 with AIRmatic
BA32.25-P-1006-04K	Nut, rear air spring at spring control arm	Nm	150
BA32.25-P-1007-04K	Air suspension pressure line at rear axle distributor	Nm	5

REAR AXLE DIFFERENTIAL

Number	Designation			Model 219 except 219.376/377	Model 219.376/377
BF35.31-P-1003-01P	Filling capacity	Rear differential assembly dia. 215 mm	Liters	1.2	1.2
BF35.31-P-1003-01P	Filling capacity	Specifications for Operating Fluids	-	Universal hypoid gear oils (specification 235.7). MB 235.7/235.74 FE hypoid gear oil A 001 989 33 03/Mobilube FE/FE Plus 75W-85	Hypoid gear oils (Specification 235.61). MB 235.61 AMG hypoid gear oil A 001 989 52 03 10
BF35.31-P-1004-01P	Filling capacity	Rear axle differential dia. 198 mm	Liters	1.1	-
BF35.31-P-1004-01P	Filling capacity	Specifications for Operating Fluids	-	Universal hypoid gear oils (specification 235.7). MB 235.7/235.74 FE hypoid gear oil A 001 989 33 03/Mobilube FE/FE Plus 75W-85	-
BF35.31-P-1005-01P	Filling capacity	Rear axle center assembly dia. 200 mm	Liters	1.1	-
BF35.31-P-1005-01P	Filling capacity	Specifications for Operating Fluids	-	Universal hypoid gear oils (specification 235.7). MB 235.7/235.74 FE hypoid gear oil A 001 989 33 03/Mobilube FE/FE Plus 75W-85	-

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

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