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Remove/install radial shaft sealing ring at output flange to rear axle - AR28.10-P-4150SYZ

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MODEL 204.08/28/93/98, 207 with TRANSMISSION 722.96 

MODEL 212, 218 with TRANSMISSION 722.96/97 

MODEL 216.3, 221.0/1 with TRANSMISSION 722.96 with 4MATIC 

Fig 1: Output Flange Radial Shaft Sealing Ring Remove/Install Components
G09976005Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
1 Remove hot film mass air flow sensor MODEL 204.08/98 with ENGINE 272 AR07.07-P-1453CV
2 Remove air duct housing MODEL 204.08/98 with ENGINE 272 AR09.20-P-0080CV
3 Detach rear reinforcement brace from frame floor assembly MODEL 204  
TORQUE SPECIFICATION *BA61.10-P-1003-01H 
4 Remove heat shields above propeller shaft Model 204  
5 Separate exhaust system at flange connection upstream of center muffler Model 204  
6 Loosen rear engine crossmember MODEL 216, 221 AR22.10-P-1180SW
Model 204, 212, 218 AR22.10-P-1180CW
7 Mark flexible coupling IMPORTANT Apply color markings of the position of the flexible coupling relative to the output flange (2) on the transfer case (4) and to the propeller shaft in order to reproduce the plant installation position.  
8 Detach flexible coupling from output flange (2) and detach propeller shaft MODEL 204 AR41.10-P-0050CW
MODEL 212, 218 AR41.10-P-0050EW
MODEL 216, 221 AR41.10-P-0050SYZ
9 Loosen pilot bushing of flexible coupling and push back propeller shaft MODEL 216, 221 AR41.10-P-0050-09SX
Model 204, 212, 218 AR41.10-P-0050-09TX
REFER TO SHOP-MADE TOOLS Drift for releasing the fitting sleeves in the flexible couplings   WF58.50-P-4110-01A
10 Detach collar nut (1) from output flange (2) INSTALLATION IMPORTANT Replace collar nut (1) and secure after tightening.  
TORQUE SPECIFICATION
MODEL 204.08/28/93/98, 207 with TRANSMISSION 722.96
MODEL 212, 218 with TRANSMISSION 722.96
MODEL 216.3, 221.0/1 with TRANSMISSION 722.96
with 4MATIC		 *BA28.10-P-1004-01E 
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.97		 *BA28.10-P-1004-01F 
SPECIAL TOOL Pin wrench Figure
SPECIAL TOOL Socket wrench bit Figure
SPECIAL TOOL Adapter Figure
11 Detach output flange (2) from output shaft IMPORTANT Use SPECIAL TOOL puller if output flange (2) is seized.  
SPECIAL TOOL Puller Figure
12 Remove radial shaft sealing ring (3) using a suitable tool NOTES
Do not damage the seat of the radial shaft sealing ring (3).
Leaks can occur otherwise.
INSTALLATION IMPORTANT Pound in new radial shaft sealing ring (3) with SPECIAL TOOL drift into rear cover, until SPECIAL TOOL drift is in contact with the rear cover.		  
SPECIAL TOOL Drift Figure
CLEANING Clean     
13 Clean output flange (2) and seat of radial shaft sealing ring (3) Assembly cleaner *BR00.45-Z-1028-04A 
INSPECT Check     
14 Check output flange (2) and seat of radial shaft sealing ring (3) at output flange (2) for wear and damage IMPORTANT Replace if necessary.  
15 Install in the reverse order    
16 Check oil level in transfer case (4) and correct if necessary   AR27.00-P-0270SYZ
IMPORTANT The transfer case (4) is connected to the oil circuit of the automatic transmission (5) at the same time. Therefore the oil level can only be checked and corrected via the automatic transmission (5).
DANGER Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running. Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
17 Carry out engine test run and check transfer case (4) for leaks
COMPLETE TRANSFER CASE

Number Designation MODEL 204, 205, 207, 212, 216, 217, 218, 221, 222 with TRANSMISSION 722.96
BA28.10-P-1004-01E Collar nut, output flange to output shaft Nm 200
COMPLETE TRANSFER CASE

Number Designation TRANSMISSION 722.97 in MODEL 212, 217, 218, 222
BA28.10-P-1004-01F Collar nut, output flange to output shaft Nm 200
FRAME FLOOR ASSEMBLY

Number Designation MODEL 204
BA61.10-P-1003-01H Bolt, rear reinforcement brace to frame floor assembly Nm 24
Fig 2: Identifying Puller (124 589 04 33 00)
G09976006Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Pin Wrench (129 589 01 07 00)
G09976007Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Socket Wrench Bit (126 589 02 09 00)
G09976008Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Adapter (100 589 02 59 00)
G09976009Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Drift (140 589 12 15 00)
G09976010Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
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