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Constant-velocity joint or rubber boot on rear halfshaft - removal and installation - AR35.30-P-0661P

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MODEL 166, 170, 171, 172, 203, 204, 207, 208, 209, 211, 212, 215, 216, 218, 219, 220, 221, 230, 231 

Fig 1: Constant-Velocity Joint On Rear Halfshaft Remove/Install Components
G09976351Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
1 Clamp rear axle shaft (37a) in vise IMPORTANT Use soft vise jaws.
Check availability of a repair kit for the rubber boot (repair possible on certain rear axle shafts (37a) only).		  
2 Remove clamps (37k) INSTALLATION IMPORTANT Replace clamps (37k), note clamp width while doing so.  
3 Remove cup seal (37i) from inner joint ring (37c) and outer joint ring (37b)   AR35.30-P-0661-01P 
INSTALLATION IMPORTANT Do not oil or grease O-ring (37n).  
FLUID SPECIFICATION MODEL 166, 170, 171, 172, 204, 207, 208, 209, 211, 212, 215, 216, 218, 219, 220, 221, 230, 231 *BF35.30-P-1001-01G 
FLUID SPECIFICATION MODEL 203 *BF35.30-P-1003-01D 
4 Dismantle constant-velocity joint   AR35.30-P-0661-03P 
5 Press joint hub (37d) off the rear axle shaft (37a)   AR35.30-P-0661-02P 
REFER TO SHOP-MADE TOOLS Shell halves (2 ea.) for pressing off and caulking the inner constant velocity joint.   WF58.50-P-3530-01A
REFER TO SHOP-MADE TOOLS Staking tool for securing joint hub on rear halfshaft   WF58.50-P-3530-07P
    SPECIAL TOOL Drift Figure
6 Remove rubber boot (37l) from opposite constant velocity joint Only if necessary.
IMPORTANT The rubber boot (37l) can be removed by way of the rear axle shaft (37a).		  
INSPECT Check     
7 Check constant velocity joints for wear   AR35.30-P-0661-03P 
IMPORTANT If the outer constant velocity joint is defective, then the rear axle shaft (37a) must be replaced.
8 Install in the reverse order    
REAR AXLE SHAFT, PLUGGED IN SHAFTS

Number Designation MODEL 166, 170, 171, 172, 204, 207, 208, 209, 211, 212, 215, 216, 218, 219, 220, 221, 230, 246 Plugged in shafts MODEL 231 Plugged in shafts
BF35.30-P-1001-01G Filling capacity for joint housing Ø82 g 80 80
Ø95 g 100 100
Ø102 g 120 120
Ø106 g 130 130
Ø112 g 140 140
Ø116 g 150 150
REAR AXLE SHAFT

Number Designation MODEL 203.004/204 except CODE 450 MODEL 203.035/045/061/081/235/245/261/281/735/745 MODEL 203.004/204 with CODE 450, inserted drive shaft
BF35.30-P-1003-01D Filling capacity for joint housing Rear axle shaft (inserted) Ø95 g 100 100
Ø102 g 120 120
Ø106 g 130 130
Ø112 g 140 140
Ø116 g 150 150
REAR AXLE SHAFT

Number Designation MODEL 203.004/204 with CODE 450, screwed drive shaft MODEL 203.006/206/706 with TRANSMISSION 722 Screwed rear axle shaft
BF35.30-P-1003-01D Filling capacity for joint housing Rear axle shaft (inserted) Ø95 g - -
Ø102 g - -
Ø106 g - -
Ø112 g - -
Ø116 g - -
REAR AXLE SHAFT

Number Designation MODEL 203.006/206/706 with TRANSMISSION 716 Inserted drive shaft MODEL 203.007/207/707 with TRANSMISSION 711, 716 except CODE 450
BF35.30-P-1003-01D Filling capacity for joint housing Rear axle shaft (inserted) Ø95 g 100 100
Ø102 g 120 120
Ø106 g 130 130
Ø112 g 140 140
Ø116 g 150 150
REAR AXLE SHAFT

Number Designation MODEL 203.007/207/707 with TRANSMISSION 722 except CODE 450 MODEL 203.007/207 with CODE 450 MODEL 203.008/208/708 with TRANSMISSION 711, 716
BF35.30-P-1003-01D Filling capacity for joint housing Rear axle shaft (inserted) Ø95 g 100 100
Ø102 g 120 120
Ø106 g 130 130
Ø112 g 140 140
Ø116 g 150 150
REAR AXLE SHAFT

Number Designation MODEL 203.007/207 with TRANSMISSION 722 with CODE 450 MODEL 203.008/016/208/216/708 with TRANSMISSION 722 MODEL 203.016/216 with TRANSMISSION 716
BF35.30-P-1003-01D Filling capacity for joint housing Rear axle shaft (inserted) Ø95 g 100 100
Ø102 g 120 120
Ø106 g 130 130
Ø112 g 140 140
Ø116 g 150 150
REAR AXLE SHAFT

Number Designation MODEL 203.018/065/218/265/718 MODEL 203.076/276
BF35.30-P-1003-01D Filling capacity for joint housing Rear axle shaft (inserted) Ø95 g 100 100
Ø102 g 120 120
Ø106 g 130 130
Ø112 g 140 140
Ø116 g 150 150
REAR AXLE SHAFT

Number Designation MODEL 203.084/284 MODEL 203.087/092/287/292
BF35.30-P-1003-01D Filling capacity for joint housing Rear axle shaft (inserted) Ø95 g 100 100
Ø102 g 120 120
Ø106 g 130 130
Ø112 g 140 140
Ø116 g 150 150
REAR AXLE SHAFT

Number Designation MODEL 203.747 with TRANSMISSION 716 MODEL 203.747 with TRANSMISSION 722
BF35.30-P-1003-01D Filling capacity for joint housing Rear axle shaft (inserted) Ø95 g 100 100
Ø102 g 120 120
Ø106 g 130 130
Ø112 g 140 140
Ø116 g 150 150
Fig 2: Identifying Drift (116 589 15 15 00)
G09976352Courtesy of MERCEDES-BENZ USA
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