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

Rear axle differential dia. 210 in MODEL 215

Rear axle shafts, inserted

Rear axle differential dia. 198 in MODEL 220

Rear axle shafts, inserted

Rear axle differential dia. 210 in MODEL 220

Rear axle shafts, inserted

Fig 1: Identifying Differential Remove/Install Components

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

25.2.05

BF35.31-P-1001-01J replaced by reference to AR35.31-P-0520-03I

Step 18

	Remove/install
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.
	Notes on self-locking nuts and bolts
	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
1	Raise vehicle with vehicle lift
2	Remove rear wheel
	Remove/install wheels
3	Detach twelve-point collar nut (9) from right rear axle shaft (5)		AR35.30-P-0115-01A
3			*BA35.30-P-1001-01A
4	Drain oil from rear axle differential (1)		AR35.31-P-0520-06I
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
		Oil drain screw	*BA35.31-P-1003-02A
	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04	BT35.31-P-0015-01A
5	Remove exhaust system from flange connection back	See: ↓ Remove complete exhaust system:
		Engine 112, 113
		Engine 613	AR49.10-P-7000M
		Engine 628	AR49.10-P-7000MB
		Engine 648	AR49.10-P-7000MZ
6	Remove right rear axle shaft (5)
7	Mark propeller shaft (3) relative to rear axle differential (1)	Apply color marking indicating position of propeller shaft relative to rear axle differential (1) to ensure that components are fitted at correct ex factory installation positions on reinstallation, otherwise vibration may occur along the drive train.
8	Detach propeller shaft (3) from rear axle differential (1)	The flexible coupling (4) remains on the propeller shaft (3). Tie the propeller shaft (3) to one side and secure to prevent it from falling.	AR41.10-P-0050-04I
9	Loosen fitted sleeves of flexible coupling (4) in flange of rear axle differential (1)	If the fitted sleeves are jammed: ↓	AR41.10-P-0050-09I
		Prepare drift for loosening fitted sleeves in flexible couplings.	WF58.50-P-4110-01A
			*BA41.10-P-1002-01A
10	Pull left rear axle shaft (5) out of rear axle differential (1) and secure using a suitable cable tie (15)	Do not damage rubber boots and the ABC multipole ring.
11	Support rear axle differential (1) with assembly attachment	Assembly attachment	Figure
12	Detach extension bracket (2) from rear axle carrier	The rear axle differential (1) can only be removed/installed when the extension bracket (2) is mounted.
12	Detach extension bracket (2) from rear axle carrier		*BA35.10-P-1001-02A
13	Detach screw connection (8) of front differential mount (7)		*BA35.10-P-1003-04A
14	Lower and remove rear axle differential (1)
15.1	Detach extension bracket (2) from rear axle differential (1)	If necessary
15.1			*BA35.10-P-1002-02A
16	Replace breather of rear axle differential (1)		*BA35.31-P-1005-02A
17	Install in the reverse order
18	Check oil level in rear axle differential (1) 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
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
		Sealant, Omnifit 100H (50 g)	*BR00.45-Z-1061-01A
		Oil filler screw for rear axle differential	*BA35.31-P-1002-02A
	Oil filler/drain screw on rear axle differential modified	Phased in as of 19.01.04	BT35.31-P-0015-01A

REAR AXLE SHAFT

Number	Designation			Model 215	Model 220
BA35.30-P-1001-01A	Collar nut, rear axle shaft to rear axle shaft flange	self-locking	Nm	350	350
BA35.30-P-1001-01A	Collar nut, rear axle shaft to rear axle shaft flange	not self-locking	Nm	320	320

DIFFERENTIAL HOUSING

Number	Designation		Model 215	Model 220
BA35.31-P-1002-02A	Oil filler screw, differential	Nm	50	50
BA35.31-P-1003-02A	Oil drain screw for rear axle differential	Nm	50	50
BA35.31-P-1005-02A	Breather, rear axle differential	Nm	30	30

PROPELLER SHAFT

Number	Designation			Model 215	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	60

EXTENSION BRACKET FOR REAR AXLE DIFFERENTIAL

Number	Designation			Model 215.374/376/379	Model 220.074/174/176/179
BA35.10-P-1001-02A	Self-locking nut securing rear extension bracket to rear axle carrier	Stage 1	Nm	95	95
BA35.10-P-1001-02A		Stage 2	∠°	-	-
BA35.10-P-1002-02A	Bolt, extension bracket to rear axle differential	Yellow	Nm	80	80
BA35.10-P-1002-02A	Bolt, extension bracket to rear axle differential	silver or blue	Nm	70	70

FRONT DIFFERENTIAL MOUNT

Number	Designation			Model 215.374/376/379	Model 220.074/174/176/179
BA35.10-P-1003-04A	Self-locking nut, rear axle differential to front differential mount	Stage 1	Nm	100	100
BA35.10-P-1003-04A		Stage 2	∠°	180	180

Fig 2: Identifying Assembly Attachment (140 589 01 62 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	Loctite 7063 cleaning spray (150 ml)	A 001 986 71 71 10