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Remove/Install Rear Axle Boot Cap On Joint Ring - AR35.30-P-0661-01P

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Model 118, 166, 170, 171, 172, 177, 203, 204, 207, 208, 209, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 247, 292 

REAR AXLE SHAFT

Number Designation Model 203.004/006/007/00 8/016/018/035/045/061/065/076/081/084/087/092/204/206/207/208/216/218/235/245/261/265/276/281/284/287/292/706/707/708/718/735/745/747 Rear axle shaft (inserted) Model 203.004/006/018/03 5/045/061/065/081/084/087/092/204/206/218/235/245/261/265/281/284/287/292/706/718/735/745 Rear axle shaft (bolted on)
BF35.30-P-1001-01D Filling capacity Inner constant velocity joint g - 120
REAR AXLE SHAFT

Number Designation MODEL 203.007/207 with TRANSMISSION 716 Bolted-on rear axle shaft except CODE 450, MODEL 203.707 with TRANSMISSION 711, 716 Bolt-on rear axle shaft except CODE 450 MODEL 203.007/207/707 with TRANSMISSION 722 Bolted-on rear axle shaft except CODE 450
BF35.30-P-1001-01D Filling capacity Inner constant velocity joint g 100 85
REAR AXLE SHAFT

Number Designation MODEL 203.007/207 with TRANSMISSION 716 Bolted-on rear axle shaft with CODE 450, MODEL 203.008/208 with TRANSMISSION 716 Bolt-on rear axle shaft, MODEL 203.708 with TRANSMISSION 711, 716 Bolted-on rear axle shaft MODEL 203.007/207 with TRANSMISSION 722 Bolted-on rear axle shaft with CODE 450, MODEL 203.008/016/208/21 6/708 with TRANSMISSION 722 Bolted-on rear axle shaft
BF35.30-P-1001-01D Filling capacity Inner constant velocity joint g 120 105
REAR AXLE SHAFT

Number Designation Model 203.016/216 with transmission 716 Rear axle shaft (bolted on) Model 203.076/276 Rear axle shaft (bolted on)
BF35.30-P-1001-01D Filling capacity Inner constant velocity joint g 150 150
REAR AXLE SHAFT

Number Designation Model 203.747 with transmission 716 Rear axle shaft (bolted on) Model 203.747 with transmission 722 Rear axle shaft (bolted on)
BF35.30-P-1001-01D Filling capacity Inner constant velocity joint g 100 85
REAR AXLE SHAFT, PLUGGED IN SHAFTS

Number Designation Model 118 Plugged in shafts Model 166, 170, 171, 172, 190, 204, 207, 208, 209, 211, 212, 215, 216, 218, 219, 220, 221, 230, 246, 292 Plugged in shafts
BF35.30-P-1001-01G Filling capacity for joint housing Ø 82 g 80 80
Ø 95 g 100 100
Ø 102 g 120 120
Ø 106 g 130 130
Ø 112 g 140 140
Ø 116 g 150 150
REAR AXLE SHAFT, PLUGGED IN SHAFTS

Number Designation Model 177 Plugged in shafts Model 217 Plugged in shafts
BF35.30-P-1001-01G Filling capacity for joint housing Ø 82 g 80 80
Ø 95 g 100 100
Ø 102 g 120 120
Ø 106 g 130 130
Ø 112 g 140 140
Ø 116 g 150 150
REAR AXLE SHAFT, PLUGGED IN SHAFTS

Number Designation Model 222 Plugged in shafts Model 231 Plugged in shafts
BF35.30-P-1001-01G Filling capacity for joint housing Ø 82 g 80 80
Ø 95 g 100 100
Ø 102 g 120 120
Ø 106 g 130 130
Ø 112 g 140 140
Ø 116 g 150 150
REAR AXLE SHAFT, PLUGGED IN SHAFTS

Number Designation Model 247 Plugged in shafts
BF35.30-P-1001-01G Filling capacity for joint housing Ø 82 g 80
Ø 95 g 100
Ø 102 g 120
Ø 106 g 130
Ø 112 g 140
Ø 116 g 150

Detach cup seal (37i) 

  1. Using protective jaw pads, clamp rear axle shaft into vise.
  2. Using a hand coping saw, saw cup seal (37i) radially in the groove on the press-in edge so that a notch arises.

    NOTES Saw carefully.

    The joint ring (37c) will otherwise be damaged.

    G07069086Courtesy of MERCEDES-BENZ USA
  3. Use a screwdriver to lift the notched area.
    G16049160Courtesy of MERCEDES-BENZ USA
  4. Starting at the standing away end, unscrew cup seal (37i) using suitable pliers until it is possible to lift the cup seal (37i) off the joint ring (37c).

    IMPORTANT

    When unscrewing the cup seal (37i) ensure that the rear axle shaft does not fall out of the joint ring (37c) before the parts have match marks placed.

  5. Mark installation position of rear axle shaft relative to joint ring (37c).
  6. Remove clamp (37k).
  7. Pull boot with boot cap (37i) from joint ring (37c) and slide down rear axle shaft.

    IMPORTANT

    If both boots are to be replaced, the boot opposite can be slid over the rear-axle shaft.

    G07069088Courtesy of MERCEDES-BENZ USA

    Mount cup seal (37i) 

  8. Replace O-ring on joint ring (37c).

    NOTES Do not oil or grease the O-ring.

    Otherwise the cup seal (37i) on the joint ring (37c) can turn.

    IMPORTANT

    Coat O-ring with spirit to make installation of the cup seal (37i) easier.

  9. Mount cup seal (37i) with clamp (37k) and slide on as far as the end stop on the joint ring (37c).

    NOTES Push on the cup seal (37i) carefully.

    Otherwise the O-ring will be damaged.

    IMPORTANT

    If necessary, drive fully home by tapping gently with a plastic mallet.

  10. Fix cup seal (37i) in circumferential groove of joint ring (37c) by applying four blows around circumference (each blow offset by 90°)
    G07069089Courtesy of MERCEDES-BENZ USA
  11. By means of even blows with a suitable hammer drive cup seal (37i) into the circumferential groove of the joint ring (37c).

    IMPORTANT

    Ensure that the boot cap (37i) seats properly.

    G07069090Courtesy of MERCEDES-BENZ USA
  12. By positioning a drift (Ø 4 mm) and applying even blows with the hammer reposition the cup seal (37i) in the groove
    G07069091Courtesy of MERCEDES-BENZ USA
  13. Measure size of joint housing.

    IMPORTANT

    The quantity of grease required depends on the size of the joint housing Using a vernier caliper measure the diameter (A) at the outer joint and the diameter (B) at the inner joint For measuring points see arrows For quantity of grease see Table.

    G07069092Courtesy of MERCEDES-BENZ USA
  14. Fill joint with new grease. Model 118, 166, 170, 171, 172, 177, 204, 207, 208, 209, 211, 212, 215, 216, 218, 219, 220, 221, 230, 247

    Plugged in shafts Model 217, 222

    Plugged in shafts Model 231

    Plugged in shafts FLUID SPECIFICATION MODEL 203 FLUID SPECIFICATION

  15. Slide boot (37l) onto cup seal (37i).

    IMPORTANT

    Ensure that the ridge (arrow) on the boot (37l) is resting between the ridges on the boot cap (37i). After the boot is pushed on, no groove on the rear axle shaft should be visible at the small diameter of the boot (37l). This indicates that the raised bead of the boot (37l) is fixed in the first groove.

    G07069093Courtesy of MERCEDES-BENZ USA
  16. Mount clamps (37k).

    IMPORTANT

    Ensure that dimension (a), measured on the inside, is not exceeded or fallen below.

    Dimensions: 

    a = 2 to 2.5 mm

G07069094Courtesy of MERCEDES-BENZ USA
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