Boot cap on joint ring removal and installation - AR35.30-P-0661-01P

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

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.

   Saw carefully.

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

   Fig 1: Detaching Cup Seal

   Courtesy of MERCEDES-BENZ USA
3. Use a screwdriver to lift the notched area.
   Fig 2: Using A Screwdriver To Lift The Notched Area

   Courtesy 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).

   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.
   Fig 3: Unscrewing Cup Seal Using Suitable Pliers

   Courtesy of MERCEDES-BENZ USA

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

   Mount cup seal (37i) 

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

   Do not oil or grease the O-ring.

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

   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).

   Push on the cup seal (37i) carefully.

   Otherwise the O-ring will be damaged.

   Fig 4: Locating O-Ring On Joint Ring

   Courtesy of MERCEDES-BENZ USA

   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°).
11. By means of even blows with a suitable hammer drive cup seal (37i) into the circumferential groove of the joint ring (37c).

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

    Fig 5: Tapping Cup Seal

    Courtesy 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.
    Fig 6: Tapping Cup Seal In Groove

    Courtesy of MERCEDES-BENZ USA
13. Measure size of joint housing.

    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 appropriate table above.

    Fig 7: Measuring Dimension Of Inner/Outer Joint Housing

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

    Plugged in shafts. Model 217, 222

    Plugged in shafts. Model 231

    Plugged in shafts MODEL 203

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

    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.

    Fig 8: Sliding Boot Onto Cup Seal

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

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

    Dimensions: 

    a = 2 to 2.5 mm

    Fig 9: Checking Boot Clamp Dimensions

    Courtesy of MERCEDES-BENZ USA