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

MODEL 220.025/026/028/083/084/087/126/128/183/184/187

MODEL 220.063/065/067/070/075/165/167/170/175 except CODE (487) Active Body Control (ABC)

Fig 1: Identifying Rear Axle Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
	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.
	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 self-locking nuts and bolts
1	Remove rear wheels
	Remove/install wheels, rotate if necessary
2	Remove exhaust system at flange connection	Refer to: Exhaust system, removal and installation of complete system: ↓
		Engine 112, 113
		Engine 137	AR49.10-P-7000L
		Engine 613	AR49.10-P-7000M
		Engine 628	AR49.10-P-7000MB
3	Detach, attach parking brake cables (112a) on automatic cable adjuster (110b) of parking brake	See: ↓
3		Remove rear brake cable	AR42.20-P-0525I
4	Remove bolts for propeller shaft intermediate bearing (106a).
5	Remove rear propeller shaft assembly (106) from rear axle differential.	Flexible disk remains on propeller shaft.
		Connect rear propeller shaft to rear axle differential	AR41.10-P-0050-04I

6	Slacken flexible coupling fitted sleeves on flange.	Put propeller shaft to one side and tie up.	AR41.10-P-0050-09I
	Drift for loosening fitting sleeves in flex disks.		WF58.50-P-4110-01A
7	Disconnect right rear brake pad contact sensor connector (S10/4x1)
8	Disconnect rpm sensor connector on the left (L6/3x1) and right (L6/4x1)
9	Disconnect the damping valve unit connector on the left (Y53x1) and right (Y54x1) and unclip line from rear axle carrier
10	Remove spring control arm cover (6g)	Remove by extracting the pin from the expansion rivet, then remove the rivet from the spring control arm and spring control arm cover.
11	Detach suspension struts (6j) at the spring control arms
12	Detach level sensor control rod (120a) from torsion bar link
	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.
13	Remove brake lines from brake hoses (111e) and seal connections.	When undoing or tightening the brake line on the brake hose (111e), take care not to twist the bracket. Use an open-end wrench as a countersupport on the sides of the brake hose fitting. Seal line connections immediately with plugs. The brake fluid reservoir must not run completely empty.
		Box wrench bit
		Set of plugs
		The brake hoses (111e) must not be twisted after being tightened (danger of cracking).
	Brake fluid notes
	Notes on installing brake hoses
	Notes on installing brake hoses	Brake line to brake hose
14	Installing guard plate	Guard plate
15	Use assembly attachment, pit hoist or floor jack beneath rear axle center assembly to support rear axle (1).	Assembly attachment
16	Remove the front rear axle suspension bolts (1c) and remove rear rear axle suspension bolts (1d)	Recut thread on frame floor with tap.
		Tighten bolts or nuts as per tightening angle	AR35.10-P-0010-08I
		Rear axle suspension bolt, front (1c)
		Rear axle suspension bolt, rear (1d)
	Bolted connection changed, front and rear rubber mounts, rear axle carrier to frame floor	As of 09.10.00 in model 220	BT35.10-P-0004-01I
17	Carefully lower the rear axle (1).	Take care to avoid trapping brake cables and lines.
18	Check rear axle (1) for damage and if necessary replace parts.
19	Install in the reverse order
20	Check oil level in rear axle differential 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
		Filling capacity of rear axle differential
		Cleaning spray, Loctite 7063 (150ml)
		Sealant, Omnifit 100H (50 g)
		Oil filler screw for rear axle differential
	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04	BT35.31-P-0015-01A
21	Bleed brake system
22	Perform a wheel alignment check
23	Check headlamp adjustment and correct if necessary
	Check and correct headlamp adjustment

SUSPENSION STRUTS

Number	Designation		Model 220.025/026/028/063/065/067/070/073/074/075/125/126/128/163/165/167/170/173/174/175/176/178/179	Models 220.083/084/087/183/184/187
BA32.25-P-1005-04B	Nut, rear strut to spring control arm	Nm	110	110

REAR AXLE CARRIER

Number	Designation				Model 215	Model 220
BA35.10-P-1001-01A	Self-locking bolt, front rear axle carrier rubber mount to frame floor	-		Nm	-	-
		with bolt Flange Ø 24 mm	Stage 1	Nm	60	60
		with bolt Flange Ø 24 mm	Stage 2	∠°	90	90
		with bolt flange Ø 26 mm	Stage 1	Nm	60	60
		with bolt flange Ø 26 mm	Stage 2	∠°	90	90
BA35.10-P-1002-01A	Self-locking bolt, rear axle carrier rear rubber mount to frame floor	-		Nm	-	-
		with bolt Flange Ø 24 mm	Stage 1	Nm	60	60
		with bolt Flange Ø 24 mm	Stage 2	∠°	90	90
		with bolt flange Ø 26 mm	Stage 1	Nm	60	60
		with bolt flange Ø 26 mm	Stage 2	∠°	90	90

REAR AXLE CENTER ASSEMBLY HOUSING

Number	Designation		Model 220
BA35.31-P-1002-02A	Oil filler screw, rear axle differential	Nm	50

PROPELLER SHAFT

Number	Designation			Model 220
BA41.10-P-1002-01A	Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential.	M10	Nm	-
BA41.10-P-1002-01A		M12	Nm	60

PROPELLER SHAFT INTERMEDIATE BEARING

Number	Designation			Model 220
BA41.40-P-1001-01A	Bolt, propeller shaft intermediate bearing to frame floor assembly	Self-tapping screw	Nm	-
		Bolt with washer	Nm	30
		Bolt with collar and self-centering tip	Nm	-
		Bolt with collar and without self-centering tip	Nm	-

BRAKE LINES, BRAKE HOSES

Number	Designation		Model 220
BA42.10-P-1001-04A	Brake pipe to brake hose	Nm	14

REAR AXLE LEVEL SENSOR

Number	Designation		Model 220 except model 220 with code 487
BA82.10-P-1001-02A	Nut, level sensor link rod to torsion bar intermediate lever	Nm	10

REAR AXLE DIFFERENTIAL

Number	Designation			Model 220.063/065/067/083/084/087/163/165/167/183/184/187	Model 220.025/026/028/070/073/075/125/126/128/170/173/178 Model 220.175 without special protection version code 979
BF35.31-P-1001-01J	Filling capacity	Rear axle center assembly	Liters	1.1	1.6
BF35.31-P-1001-01J	Filling capacity	Specifications for Operating Fluids	Sheet	BB00.40-P-0235-07A	BB00.40-P-0235-07A

Fig 2: Identifying Box Wrench Bit (000 589 75 03 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Guard Plate (220 589 01 31 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Assembly Attachment (140 589 01 62 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Set Of Stop Plugs (129 589 00 91 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