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

MODEL 204, 207 

Fig 1: Identifying Differential Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
		While working on the rear axle care must be taken to ensure that the surfaces of all aluminum components do not get any scratches, cracks and notches. Otherwise the service life of the of the parts will be reduced.
1	Secure vehicle on vehicle lift		AR00.60-P-0100CW
2	Remove left rear axle shaft (37)		AR35.30-P-0620CW
3	Remove left and right rear diagonal strut	Model 207.4
			*BA61.10-P-1007-01H
			*BA61.10-P-1008-01H
			*BA61.10-P-1009-01H
4	Remove exhaust system from flange connection back	Vehicles with gasoline engine	AR49.10-P-7100CW
5	Detach propeller shaft (7) from joint flange on differential (50)		AR41.10-P-0050CW
6	Loosen fitting sleeves of flex disk on joint flange of differential (50)		AR41.10-P-0050-09TX
	Drift for loosening fitting sleeves in flex disks.		WF58.50-P-4110-01A
7	Lash down the differential (50) on the rear axle carrier (4) with tensioning strap
8	Remove struts	Model 204.9	AR35.10-P-0042-01CWG
			*BA35.10-P-1007-01N
			*BA35.10-P-1008-01N
9	Open luggage compartment, remove spare tire and remove rubber plug from spare tire well
10	Remove left and right bolt (3) of rear differential mount		*BA35.10-P-1006-01N
11	Support differential (50) with transmission jack and transmission plate and lash down securely
12	Loosen lashing of rear axle differential (50) with rear axle carrier (4)
13	Remove bolt (5) of front differential mount (8)
		Installation:  The adjusting disk (9) must be reinstalled.	*BA35.10-P-1005-01N
14	Lower the differential (50) slightly
15	Secure right-hand rear axle shaft to prevent it from falling down
16	Pry right-hand rear axle shaft out of the differential (50)	Do not  fasten assembly lever to the protective ring (37a). Support assembly lever on differential e.g with a socket wrench.
		Installation:  Install new retaining ring (37o) on inner splined profile.
17	Lower differential (50) further
18	Install in the reverse order
19	Check oil level in differential (50) and correct if necessary		AR35.31-P-0520-03SX
			*BA35.31-P-1002-02H
		Sealant, Omnifit 100H (50 g)	*BF35.31-P-1001-01T  *BR00.45-Z-1061-01A
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
20	Perform wheel alignment check	Model 204	AR40.20-P-0200CW

REAR AXLE CARRIER

Number	Designation		Model 204	Model 207
BA35.10-P-1005-01N	Differential to front adapter	Nm	65	65
BA35.10-P-1006-01N	Bolt, rear axle differential to rear crossmember	Nm	170	170
BA35.10-P-1007-01N	Nut, strut to body	Nm	25	-
BA35.10-P-1008-01N	Bolt, strut to rear rubber mount of rear axle carrier	Nm	25	-

DIFFERENTIAL HOUSING

Number	Designation		Model 204	Model 207
BA35.31-P-1002-02H	Oil filler screw, differential	Nm	50	50

FRAME FLOOR ASSEMBLY

Number	Designation		Model 207.4
BA61.10-P-1007-01H	Bolt, rear diagonal strut on spare wheel well	Nm	80
BA61.10-P-1008-01H	Bolt, rear diagonal strut on longitudinal member	Nm	80
BA61.10-P-1009-01H	Bolt, rear diagonal strut to bracket	Nm	17

DIFFERENTIAL

Number	Designation			Model 204 except model 204.077/277/377 with code 471, P30	Model 204.077/277/377 with code 471, P30
BF35.31-P-1001-01T	Filling capacity	Differential 187 FE, Ø 187 mm	Liters	0.95	-
			Sheet	BB00.40-P-0235-07 A	-
		Differential 200 FE, Ø 200 mm	Liters	1.1	-
			Sheet	BB00.40-P-0235-07 A	-
		Differential 215 FE, Ø 215 mm	Liters	1.2	1.2
			Sheet	BB00.40-P-0235-07 A	BB00.40-P-0235-61 A

DIFFERENTIAL

Number	Designation			Model 207
BF35.31-P-1001-01T	Filling capacity	Differential 187 FE, Ø 187 mm	Liters	0.95
			Sheet	BB00.40-P-0235-07 A
		Differential 200 FE, Ø 200 mm	Liters	1.1
			Sheet	BB00.40-P-0235-07 A
		Differential 215 FE, Ø 215 mm	Liters	1.2
			Sheet	BB00.40-P-0235-07 A

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	Loctite 7063 cleaning spray (150 ml)	A 001 986 71 71 10