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Remove/install front axle shafts - AR33.30-P-0620I

WARNING: This page is about a different car, the 2009 Mercedes-Benz E550 and 2008 Mercedes-Benz E550. However, it is still accessible from the selected car via links, so may be relevant.

MODEL 220.08/18, 211.08/28/09/29 

Fig 1: Identifying Front Axle Shafts Components
G07279785Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 211 

MODIFICATION NOTES

9.8.08 SWZ 140 589 00 33 00 for prying off upper ball joint added Operation step 3 AR33.20-P-0500-01N
REMOVINGINSTALLING Remove/install     
DANGER 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
DANGER 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
NOTES When working on the front-end assembly, be careful not to scratch, mark or notch the surfaces of aluminum parts. Otherwise the service life of the parts will be affected    
NOTES Notes on self-locking nuts and bolts All models AH00.00-N-0001-01A
INSTALLATION IMPORTANTInstallation  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. Model 211
IMPORTANT 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.		  
2 Completely discharge all air from air spring with STAR DIAGNOSIS IMPORTANT Residual pressure in spring strut up to 3.5 bar.  
3 Raise vehicle with vehicle lift    
4 Remove front wheels    
REFER TO MAINTENANCE Remove/install wheels, rotate if necessary AP40.10-P-4050Z
5 Unscrew hexagon collar bolt (61a) from right front axle shaft (60a) or left front axle shaft (60b)   AR33.30-P-0620-05P 
TORQUE SPECIFICATION *BA33.30-P-1003-02C 
6 Remove lower engine compartment paneling Model 211 AR61.20-P-1105T
Model 220 AR61.20-P-1105M
7 Remove brake caliper from front axle Model 211 AR42.10-P-0070T
Model 220
NOTES Attach brake caliper to vehicle without tension to relieve brake hose so that it is not damaged during repair.
IMPORTANT The brake hose does not have to be unscrewed from the brake caliper.		 AR42.10-P-0070I
8 Remove front left or right RPM sensor Model 220
IMPORTANT Remove RPM sensor of brake caliper and hang up to one side. Do not loosen connector of electrical line to RPM sensor		 AR42.30-P-0712I
9 Push supporting joint (7) out of steering knuckle (5) NOTES After prying off at the supporting joint screw the nut on again, otherwise the steering knuckle may fall down and become damaged. Only unscrew the nut when the steering knuckle is removed.  
Model 211 AR33.20-P-0440-01VM 
TORQUE SPECIFICATION *BA33.20-P-1017-01A 
SPECIAL TOOL *140589006300
SPECIAL TOOL *203589003300
Model 220 AR33.20-P-0440-01IW
TORQUE SPECIFICATION *BA33.20-P-1010-01F 
SPECIAL TOOL *140589006300
SPECIAL TOOL *202589023300
10 Press tie rod joint (10a) out of steering knuckle (5)   AR46.40-P-0200-02IW
TORQUE SPECIFICATION *BA46.40-P-1001-01E 
SPECIAL TOOL *140589006300
SPECIAL TOOL *124589023300
SPECIAL TOOL *140589003300
11 Push follower joint of upper transverse control arm out of steering knuckle (5) NOTES The follower joint must be removed, otherwise the follower joint is damaged by hard pulling or excessive angles.  
TORQUE SPECIFICATION *BA33.20-P-1018-01A 
Model 211 AR33.20-P-0500-01VM 
SPECIAL TOOL *210589046300
SPECIAL TOOL *202589023300
Model 220 AR33.20-P-0500-01N
TORQUE SPECIFICATION *BA33.20-P-1007-01F 
SPECIAL TOOL *210589046300
SPECIAL TOOL *202589023300
SPECIAL TOOL *140589003300
12 Detach stabilizer bar link rod from stabilizer bar Model 211 AR32.20-P-0300-02VM
TORQUE SPECIFICATION *BA32.20-P-1002-02B 
Model 220 AR32.20-P-0300-02VB
TORQUE SPECIFICATION *BA32.20-P-1002-02H 
13 Remove front suspension strut from transverse control arm Model 211 AR33.20-P-0500-06VM 
TORQUE SPECIFICATION *BA32.25-P-1012-04B 
14 Move steering knuckle (5) out of supporting joint (7)    
15 Remove steering knuckle (5) and move right front axle shaft (60a) or left front axle shaft (60b) out of front axle shaft flange IMPORTANT Avoid damaging the rubber boots on the front axle shaft and the rubber boot on the supporting joint (7).
IMPORTANT If necessary, to loosen the front axle shaft, screw in the hexagon collar bolt (61a) a few threads again and knock out the front axle shaft a little using a rubber hammer.		  
16.1 Push out right front axle shaft (60a) and remove NOTES Do not damage the rubber boots and RPM sensor rotor. To avoid damaging the wheel bearings, the vehicle must not be moved on its wheels with the front axle shaft removed.
IMPORTANT Mount the SPECIAL TOOL chain onto the pot of the right-hand front axle shaft. Ensure that the chain is attached as close as possible towards the front axle gear (50).
NOTES When moving the front axle shaft in and out, ensure that the sealing ring is not damaged by the splines and the circlip.		 AR33.30-P-0620-02P 
SPECIAL TOOL *203589036300
16.2 Knock out and remove left front axle shaft (60b) NOTES Do not damage the plastic guard ring (60m), rubber boots and RPM sensor rotor. To avoid damaging the wheel bearings, the vehicle must not be moved on its wheels with the front axle shaft removed. AR33.30-P-0620-03P 
INSPECT Checking     
17 Check joints and rubber boots of front axle shaft for leaks and damage IMPORTANT New front axle shaft must be installed if damaged is found.  
18 Check radial sealing ring in front axle gear (50) of right-hand front axle shaft (60a) for damage IMPORTANT If damaged the radial sealing ring must be replaced:↓
Install new radial sealing ring on outside right of front axle gear		  
Model 211 AR33.30-P-0540VM 
Model 220 AR33.30-P-0540P
19 Install in the reverse order    
20 Charge air spring with STAR DIAGNOSIS at design level. NOTES The wheels must not touch the ground while pressurizing because the air bellows in the suspension strut will be destroyed if pressurized with the suspension compressed.
IMPORTANT Pressurize to 5 bar.		  
21 Activate SBC brake system using STAR DIAGNOSIS Model 211
IMPORTANT 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.		  
FRONT AXLE SHAFT

Number Designation Model 211.08/09/28/29 Model 220.08/18
BA33.30-P-1003-02C Collar bolt, front axle shaft to front axle shaft flange Stage 1 Nm 70 70
Stage 2 ∠° 90 90
WHEEL LOCATION, HUB

Number Designation Model 211.08/09/28/29
BA33.20-P-1017-01A Self-locking nut, supporting joint to steering knuckle Stage 1 Nm 70
Stage 2 ∠° 50
BA33.20-P-1018-01A Self-locking nut, upper wishbone follower joint to steering knuckle Stage 1 Nm 20
Stage 2 ∠° 90
WHEEL LOCATION, HUB

Number Designation Model 220.08/18
BA33.20-P-1007-01F Self-locking nut, upper wishbone follower joint to steering knuckle Stage 1 Nm 20
Stage 2 ∠° 90
BA33.20-P-1010-01F Self-locking nut, supporting joint to steering knuckle Stage 1 Nm 70
Stage 2 ∠° 50
TIE ROD

Number Designation Model 220.083/084/087/183/184/187 Model 211.08/09/28/29
BA46.40-P-1001-01E Self-locking nut, tie rod to steering knuckle Stage 1 Nm 55 55
Stage 2 ∠° - -
FRONT AXLE STABILIZER BAR

Number Designation Model 211.08/09/28/29
BA32.20-P-1002-02B Self-locking nut, connecting rod to torsion bar M10 Nm -
M10 1.5 Nm -
M12 1.5 Nm 95
M14 1.5 Nm -
FRONT AXLE STABILIZER BAR

Number Designation Model 220.083/084/087/183/184/187
BA32.20-P-1002-02H Nut, link rod to stabilizer bar Nm 95
SUSPENSION STRUTS

Number Designation Model 211.08/09/28/29
BA32.25-P-1012-04B Nut of shock-absorber strut to transverse control arm Nm 162
Fig 2: Identifying Thrust Piece (140 589 00 63 00)
G07279786Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Puller (202 589 02 33 00)
G07279787Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Puller (124 589 02 33 00)
G07279788Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Chain (203 589 03 63 00)
G07279789Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 6: Identifying Puller (203 589 00 33 00)
G07279790Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 7: Identifying Thrust Washer M 10X1.5 (210 589 04 63 00)
G07279791Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 8: Identifying Puller (140 589 00 33 00)
G07279792Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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