Assemble Hub Reduction Gear - AR35.25-P-0650-02GWX

Model 463.234 

up to model year 2019 

with code ZQ0 (G 500 4x4 ²  ) 

Model 463.255 

up to model year 2019 

with code MUK2 (USA or Canada vehicle model designation) 

with code ZQ0 (G 500 4x4 ²  ) 

Model 463.274 

up to model year 2019 with code LQ0 (G650 Landaulet) 

	Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
	Risk of injury.  Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	Risk of injury.  Moving parts can pinch, crush or, in extreme cases even sever extremities.	No parts of the body or limbs should be within the operating area of mechanical components when moving components.	AS00.00-Z-0009-01A
	Notes for repair work on hub reduction gear		AH33.25-P-0650-01GWX
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Notes on repair work on suspension components		AH00.00-P-0100-01A
	Determine shims		AR35.25-P-0650-03GWX

Number	Designation		Model 463.234 up to model year 2019 with code ZQ0 (G 500 4x42 ) Model 463.255 up to model year 2019 with code MUK2 (USA or Canada vehicle model designation) with code ZQ0 (G 500 4x42 ) Model 463.274 up to model year 2019 with code LQ0 (G650 Landaulet)
BA35.25-P-1001-02A	Preload, clamp nut to wheel hub	Nm	200

Number	Designation		Model 463.234 up to model year 2019 with code ZQ0 (G 500 4x42 ) Model 463.255 up to model year 2019 with code MUK2 (USA or Canada vehicle model designation) with code ZQ0 (G 500 4x42 ) Model 463.274 up to model year 2019 with code LQ0 (G650 Landaulet)
BA35.25-P-1002-02A	Clamp nut to wheel hub	Nm	80

Number	Designation		Model 463.234 up to model year 2019 with code ZQ0 (G 500 4x42 ) Model 463.255 up to model year 2019 with code MUK2 (USA or Canada vehicle model designation) with code ZQ0 (G 500 4x42 ) Model 463.274 up to model year 2019 with code LQ0 (G650 Landaulet)
BA35.25-P-1003-02A	Bolt to clamping nut	Nm	40

Number	Designation		Model 463.234 up to model year 2019 with code ZQ0 (G 500 4x42 ) Model 463.255 up to model year 2019 with code MUK2 (USA or Canada vehicle model designation) with code ZQ0 (G 500 4x42 ) Model 463.274 up to model year 2019 with code LQ0 (G650 Landaulet)
BA35.25-P-1004-02A	Screw plug for screw of clamp nut on wheel hub	Nm	25

Number	Designation		Model 463.234 up to model year 2019 with code ZQ0 (G 500 4x42 ) Model 463.255 up to model year 2019 with code MUK2 (USA or Canada vehicle model designation) with code ZQ0 (G 500 4x42 ) Model 463.274 up to model year 2019 with code LQ0 (G650 Landaulet)
BA35.25-P-1005-02A	Screw plug, wheel hub	Nm	40

Number	Designation		Model 463.234 up to model year 2019 with code ZQ0 (G 500 4x42 ) Model 463.255 up to model year 2019 with code MUK2 (USA or Canada vehicle model designation) with code ZQ0 (G 500 4x42 ) Model 463.274 up to model year 2019 with code LQ0 (G650 Landaulet)
BA35.25-P-1006-02A	Hub reduction gear housing screws	Nm	75

Number	Designation		Model 463.234 up to model year 2019 with code ZQ0 (G 500 4x42 ) Model 463.255 up to model year 2019 with code MUK2 (USA or Canada vehicle model designation) with code ZQ0 (G 500 4x42 ) Model 463.274 up to model year 2019 with code LQ0 (G650 Landaulet)
BA35.25-P-1007-02A	Screw, gearwheel to drive shaft	Nm	25

Number	Designation		Model 463.234 up to model year 2019 with code ZQ0 (G 500 4x42 ) Model 463.255 up to model year 2019 with code MUK2 (USA or Canada vehicle model designation) with code ZQ0 (G 500 4x42 ) Model 463.274 up to model year 2019 with code LQ0 (G650 Landaulet)
BA35.25-P-1008-02A	Screw, wheel hub cover to hub reduction gear housing	Nm	10

Number	Designation		Model 463 up to model year 2019
BA35.30-P-1007-02A	Drain screw at portal drive	Nm	120

Number	Designation	Order number
BR00.45-Z-1017-06A	MB multipurpose grease, 400 g	A 001 989 34 51 11
BR00.45-Z-1046-04A	Loctite 7063 (400 ml) cleaning spray	A 001 986 71 71 09
BR00.45-Z-1066-01A	Loctite 243	A 613 989 09 71 09
BR00.45-Z-1078-02A	Loctite 2701	Henkel AG & Co. KGaA
BR00.45-Z-1128-01A	Pipe sealant, medium strength	Adolf Wurth GmbH & Co. KG
BR00.45-Z-1129-01A	Surface sealant, green	Adolf Wurth GmbH & Co. KG
BR00.45-Z-1132-06A	LUKOIL TRANSMISSION MN TM-4/5 75W-90	OOO LLK-International, Moscow, Russia

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1. Prepare assembly tool and commercially available devices/tools.

   Commercially available devices/tools 

   Screw press

   Soft face hammer

   Heating oven

   While the work is being carried out, it is necessary at various times to lock the assembly tool to prevent it from turning or to unlock it and align it vertically or horizontally.

   Pre-assembly of wheel hub (36) 

2. Position thrust plate (30) on wheel hub (36).

   Align chamfer with outside edge.

3. Place wheel hub (36) on a surface to allow the tapered roller bearing (31) to be pressed on.

   The wheel studs must remain free to move if they were not removed.

4. Remove bearing shell (31 a) of tapered roller bearing (31), position bearing cage on wheel hub (36) and press onto wheel hub (36) as far as the stop using drift.
5. Pull wheel studs into wheel hub (36) using suitable means.

   Ensure correct alignment of the wheel studs.

6. Position bearing shell (31a) on tapered roller bearing (31) again.
7. Fit thrust plate (2) on wheel hub (36).

   Align the chamfer of the thrust plate (2) to the outside.

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   Pre-assembly of relay spur gear (24) 

8. Mark bearing shells and associated bearing cages of tapered roller bearings (23, 25).

   The tapered roller bearing (23) is located on the short side.

   Do not mix up the bearing cages and bearing shells.

9. Position relay spur gear (24) on a suitable mat position and press on first bearing cage using sleeve.
10. Turn relay spur gear (24) over, set it down on a suitable base and press in the other bearing cage using sleeve.

    Do not rest the underside of the relay spur gear (24) on the bearing cage installed there.

    This causes irreparable damage to the bearing.

11. Complete the tapered roller bearings unit (23, 25) again.
12. Measure height dimension (B) of relay spur gear assembly (23, 24, 25) and determine thickness of shims.

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    Pre-assembly of inner housing (12) 

13. Position shims (1) in bearing seat and press in bearing shells (25a) on long side of relay spur gear up to end stop using drift.
14. Press in bearing shell (28 a) of tapered roller bearing of wheel hub up to end stop using drift.

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15. Heat pulse ring (11) to approx. 80°C and install on long side of gearwheel (34).

    Commercially available device 

    Hot plate

16. Press in deep-groove ball bearing (20) up to end stop using sleeve.
17. Install retaining ring (3).
18. Coat new shaft seal (21) with multipurpose grease and install flush with housing edge.
19. Lightly oil gearwheel (34) with and press into deep-groove ball bearing (20) up to end stop using drift.
20. Install retaining ring (4).
21. Coat gearing of drive shaft with multipurpose grease and insert drive shaft into gearwheel (34).

    The drive shafts are different lengths on the left and right sides.

22. Secure gearwheel (34) of drive shaft using blocking device to prevent it from turning.
23. Coat screw (8) with thread lock and tighten
24. Fix bearing cage of tapered roller bearing of wheel hub in bearing shell (28a).

    e.g. using cable ties.

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    Preparation for assembly of housing halves 

25. Fix wheel hub (36) in assembly tool.
26. Remove bearing shell (31a) of tapered roller bearing (31) and place down on a suitable mat.

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    Assembly of external housing (13) 

    The new caulking points (9) should be 120° apart and lie on the bisectors of the previous caulking points (9). The minimum distance to the nearest caulking point (9) must not be less than 30°.

    Replace the external housing (13) before commencing the work if the minimum distance would be undershot during assembly.

27. Press in bearing shell (23a) up to end stop using drift.

    Note direction of installation. Use the bearing shell (23a) on the short side of the previously assembled spur gear.

28. Press in cylindrical roller bearing (22) up to end stop using sleeve.
29. Apply new caulking points (9) 120° apart to secure the cylindrical roller bearing (22).
30. Press previously set-aside bearing shell of tapered roller bearing (31) into external housing (13) from outside up to end stop using drift.
31. Coat new shaft seal (32) with multipurpose grease and install in external housing (13) from outside flush with upper edge of housing using suitable means.

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32. Position screw (48) over wheel hub in bore.

    It is not possible to position the screw (48) later.

33. Guide external housing over wheel hub and fix on assembly tool.

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34. Install gearwheel (33) of wheel hub (36).
35. Install retaining ring (29).
36. Oil previously assembled relay spur gear (24) with bearing cages with and install in external housing (13).

    The upper edge of the relay spur gear (24) and the upper edge of the gearwheel (33) must sit flush.

    Note direction of installation. Install relay spur gear (24) so that the bearing cage is seated in the associated bearing shell. The short side points downwards.

37. Check seating of dowel pins (7) and adjust if necessary.

    The dowel pins (7) must be installed up to the end stop in the external housing (13) in the correct position.

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    Assembly of housing halves 

38. Clean sealing surfaces between housing halves with cleaning spray and degrease.

    The sealing surfaces must be free of oil and grease. Otherwise sealing problems can occur.

39. Apply sealant evenly to sealing surfaces between housing halves.
40. Position inner housing on external housing.
41. Tap alternately and evenly in the area of the dowel pins until the two housing halves are flush with each other.
42. Tighten screw (52) .

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43. Tighten screws (37 to 43) in the sequence shown

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44. Heat tapered roller bearing (28) to 120°C.

    Commercially available device 

    Heating oven

45. Position heated tapered roller bearing (28) on bearing shell (28a).
46. Coat contact surface of insertion device and thread of wheel hub (36) with multipurpose grease.
47. Attach insertion device to thread of wheel hub (36).
48. Preload tapered roller bearing (28) using insertion device .

    Do not remove the insertion device.

49. Remove excess sealant from housing using suitable means.

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    Commercially available tools 

    Soft face hammer

50. Tighten screws (44 to 51) in the sequence shown .
51. Coat screw (5) with pipe sealant and tighten .

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52. Lightly oil tapered roller bearing (28) with oil.
53. Rotate housing or shaft of wheel hub (36) under preload and remove insertion device.
54. Position thrust plate with groove (26) on tapered roller bearing (28).

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    Perform operation steps  55 to  59 in quick succession.

55. Clean screw for clamp nut (27) with cleaning spray and apply thread locking agent to the thread.
56. Tighten clamp nut (27) using blocking device .

    Note direction of installation.

57. Turn housing or wheel hub so that bore of screw (6) and bore for screw of clamp nut (27) are in alignment.
58. Tighten screw of clamp nut (27)
59. Coat thread of screw (6) with pipe sealant and tighten screw (6) .
60. Clean sealing surfaces (C, D) with cleaning spray.

    The sealing surfaces (C, D) must be free of oil and grease.

    Otherwise sealing problems can occur.

61. Apply sealant to sealing surface (C).

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62. Position cap and tighten screws in a cross pattern .
63. Tighten oil filler screw with new sealing ring slightly by hand.

    Add the oil only in installed condition.

64. Screw in drain screw securely with a new sealing ring .