Boot cap on joint ring removal and installation - AR35.30-P-0661-01P

MODEL 166, 170, 171, 172, 203, 204, 207, 208, 209, 211, 212, 215, 216, 218, 219, 220, 221, 230 mated with rear axle 

Remove boot cap 

1. Using protective jaw pads, clamp rear halfshaft into vice.
2. Using a hand coping saw, saw cup seal (37i) radially in the groove on the press-in edge so that a notch arises.

   Saw carefully. The joint ring (37c) will otherwise be damaged.

   Fig 1: Sawing Cup Seal Using Hand Coping Saw

   Courtesy of MERCEDES-BENZ USA
3. Use a screwdriver to lift the notched area.
   Fig 2: Identifying Notched Area Using Screwdriver

   Courtesy of MERCEDES-BENZ USA
4. Starting at projecting end, use suitable pliers to unscrew cup seal (37i) until cup seal (37i) can be lifted off joint ring.

   When rotating on the boot cap (37i) avoid allowing the rear halfshaft to drop out of the joint ring before the relative alignment positions of the components have been marked.

5. Mark installation position of rear axle shaft relative to joint ring.
6. Remove hose clamps.
7. Pull boot with boot cap (37i) off joint ring and slide down rear halfshaft.

   If both boots are to be replaced, the boot opposite can be slid over the rear-axle shaft.

   Fig 3: Lifting Cap Seal Off Joint Ring

   Courtesy of MERCEDES-BENZ USA

   Install boot cap. 

8. Replace O-ring on joint ring (37c).

   Coat O-ring with spirit to make installation of the cup seal (37i) easier.

   Do not oil or grease the O-ring. The cup seal (37i) can otherwise turn on the joint ring (37c).

9. Mount cup seal (37i) with hose clamp and slide all the way onto the joint ring (37c). If necessary, drive fully home by tapping gently with a plastic mallet.

   Push on the cup seal (37i) carefully. The O-ring will otherwise be damaged.

Fig 4: Mounting Cup Seal With Hose Clamp And Slide All Way Onto Joint Ring
Courtesy of MERCEDES-BENZ USA
10. Fix cup seal (37i) in circumferential groove of joint ring (37c) by applying four blows around circumference (each blow offset by 90°).
11. Apply even blows using a suitable hammer to drive the cap seal into the groove extending along the periphery of the joint ring.

    Check the cup seal is correctly seated.

    Fig 5: Applying Even Blows Using Suitable Hammer To Drive Cap Seal Into Groove Extending Along Periphery Of Joint Ring

    Courtesy of MERCEDES-BENZ USA
12. Through positioning a drift (∠° 4 mm) and applying uniform blows with the hammer, reposition the cup seal into the groove.
    Fig 6: Applying Uniform Blows With Hammer, Reposition Cup Seal Into Groove

    Courtesy of MERCEDES-BENZ USA
13. Measure size of joint housing.

    The quantity of grease required depends on the size of the joint housing. Using a vernier caliper, measure the diameter (A) at the outer joint and the diameter (B) at the inner joint.

    Fig 7: Measuring Size Of Joint Housing

    Courtesy of MERCEDES-BENZ USA
14. Fill joint with new grease .
15. Slide boot (37l) onto cup seal (37i).

    Ensure that the ridge (arrow) on the boot (37l) is resting between the ridges on the boot cap (37i).

    After the boot is pushed on, no groove on the rear axle shaft should be visible at the small diameter of the boot (37l). This indicates that the raised bead of the boot (37l) is fixed in the first groove.

    Fig 8: Identifying Sliding Boot Onto Cup Seal

    Courtesy of MERCEDES-BENZ USA
16. Install hose clamps (37k).

    Ensure that dimension (a), measured on the inside, is not exceeded or fallen below.

    Dimension: 

    a = 2...2.5 mm

    Fig 9: Installing Hose Clamps

    Courtesy of MERCEDES-BENZ USA