Replace radial sealing ring on connecting flange of rear axle shaft - AR35.31-P-0540I

Rear axle differential dia. 198 in MODEL 220.063/065/067/083/084/087/165/167/183/184/187

Rear axle differential dia. 210 in MODEL 215.375/378, 220.025/026/028/070/075/126/128/170/175/178 rear axle center assembly 210E

Shown on rear axle center assembly dia. 198 mm

Fig 1: Replacing Rear Axle Shaft Radial Sealing Ring - Shown On Rear Axle Center Assembly

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.
1	Raise vehicle
2	Drain oil from rear axle differential		AR35.31-P-0520-06I
		Cleaning spray, Loctite 7063 (150ml)	*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
3	Remove rear axle differential (50)		AR35.31-P-0520I
4	Clamp rear axle differential (50) in assembly stand		AR35.31-P-0540-06B
		Assembly stand	Fig 2
		Supports (2 ea.)	Fig 3
		Supports	Fig 4
5	Detach extension bracket (54a) from rear axle center assembly (50)	Replace collar bolt securing extension bracket to rear axle differential (54b).	*BA35.10-P-1002-02A
6.1	Remove end cover (54) with machined sealing surface	If a replacement part end cover is fitted it is absolutely essential to observe whether the sealing surface is machined or not. Use suitable sealant. Fit end cover: ↓
		Rear axle center assembly dia. 198 mm up to 22.05.00	AR35.31-P-0550-28A
		Sealant	*BR00.45-Z-1010-01A
		Bolt + washer or flange bolt	*BA35.31-P-1001-02A
		Rear axle center assembly dia. 210 mm in rear axle center assembly 210E up to 14.05.00	AR35.31-P-0550-28E
		Sealant	*BR00.45-Z-1010-01A
		Bolt + washer or flange bolt	*BA35.31-P-1001-02A
	Rear axle differential end cover with non-machined sealing surface		BT35.31-P-0014-01A
6.2	Remove end cover (54) with non-machined sealing surface	Fit end cover: ↓
		Rear axle center assembly dia. 198 mm as of 23.05.00	AR35.31-P-0550-28AA
		Squeeze gun	Fig 5
		Loctite sealant 5970	*BR00.45-Z-1013-01A
		Bolt + washer or flange bolt	*BA35.31-P-1001-02A
		Rear axle center assembly dia. 210 mm in rear axle center assembly 210E as of 15.05.00	AR35.31-P-0550-28EA
		Squeeze gun	Fig 5
		Loctite sealant 5970	*BR00.45-Z-1013-01A
		Bolt + washer or flange bolt	*BA35.31-P-1001-02A
7	Detach retaining ring (30)	Replace retaining ring.	AR35.31-P-0540-01A
7	Detach retaining ring (30)	Removal and installation tool	Fig 6
8	Pull out connecting flange (33)	Check contact surface for radial sealing ring (32) on connecting flange; in the case of galling: ↓ Replace connecting flange
		Check, adjust axial play of connecting flange	AR35.31-P-0540-02C
		Axial play between connecting flange and differential housing	*BE35.31-P-1001-05A
	Radial seal on side of rear axle housing and connecting flange modified	As of 01.10.01 with model 220 with rear axle center assembly dia. 198 mm and with model 215, 220 with rear axle center assembly dia. 210 mm in rear axle center assembly 210E	BT35.31-P-0013-01B
9.1	Press protection ring off connecting flange (33)	As of 01.10.01 with model 220 with rear axle center assembly dia. 198 mm and with model 215, 220 with rear axle center assembly dia. 210 mm in rear axle center assembly 210E	AR35.30-P-0620-05R
		If a new radial sealing ring (32) is installed for the first time, a new protection ring must also be installed. This is the only way to ensure a proper seal.
		Drift	Fig 8
10	Press off radial sealing ring (32)	Replace radial sealing ring and coat the lip with universal hypoid transmission oil.	AR35.31-P-0540-05C
	Universal hypoid gear oils		BB00.40-P-0235-07A
		Drift	Fig 7
	Radial seal on side of rear axle housing and connecting flange modified	As of 01.10.01 with model 220 with rear axle center assembly dia. 198 mm and with model 215, 220 with rear axle center assembly dia. 210 mm in rear axle center assembly 210E	BT35.31-P-0013-01B
11	Replace breather (55) on rear axle center assembly		*BA35.31-P-1005-02A
12	Install in the reverse order
13	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	*BF35.31-P-1001-01J
		Cleaning spray, Loctite 7063 (150ml)	*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

TEST VALUES FOR CONNECTING FLANGE/DIFFERENTIAL HOUSING

Number	Designation		Model 215	Model 220
BE35.31-P-1001-05A	Axial play between connecting flange and differential housing	mm	0.03 to 0.3	0.03 to 0.3

EXTENSION BRACKET FOR REAR AXLE CENTER ASSEMBLY

Number	Designation			Model 215.374/376/379	Model 220.025/026/028/063/065/067/070/073/075/083/084/087/125/126/128/165/167/170/173/175/178/183/184/187
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

REAR AXLE CENTER ASSEMBLY HOUSING

Number	Designation				Model 215	Model 220
BA35.31-P-1001-02A	Bolt, end cover to rear axle differential	Bolt+washer		Nm	-	-
		Flange bolt (TORX, internal serrations)	Stage 1	Nm	30	30
		Flange bolt (TORX, internal serrations)	Stage 2	∠°	45	45
BA35.31-P-1002-02A	Oil filler screw, rear axle 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

REAR AXLE DIFFERENTIAL

Number	Designation			Model 215.373/375/378	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	1.6	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	BB00.40-P-0235-07A

Fig 2: Identifying Assembly Stand (129 589 00 31 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Supports (2 Ea.) (140 589 40 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Supports (220 589 01 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Squeeze Gun (112 589 00 25 00)

Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Removal And Installation Tool (116 589 01 62 00)

Courtesy of MERCEDES-BENZ USA

Fig 7: Identifying Drift (140 589 10 15 00)

Courtesy of MERCEDES-BENZ USA

Fig 8: Identifying Drift (140 589 16 15 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-1010-01A	Sealing compound, Hylomar universal sealant, 80 ml	A 001 989 25 20
BR00.45-Z-1013-01A	Loctite sealant 5970	A 003 989 98 20
BR00.45-Z-1046-04A	Cleaning spray, Loctite 7063 (150ml)	A 001 986 71 71 10