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Remove/install front axle shafts - AR33.30-P-0620CWX

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MODEL 204.08/09/28/29/38/93/98/99 

MODEL 207, 212, 218 with CODE M005 (4MATIC) 

Shown on model 204 

Fig 1: Front Axle Shafts Remove/Install Components - Shown On Model 204 (1 Of 2)
G09976259Courtesy of MERCEDES-BENZ USA
Fig 2: Front Axle Shafts Remove/Install Components - Shown On Model 204 (2 Of 2)
G09976260Courtesy of MERCEDES-BENZ USA
REMOVING Remove     
1.1 Remove front section of lower engine compartment paneling MODEL 204.08 with ENGINE 272, 276
MODEL 204.38 with ENGINE 276
MODEL 207 with ENGINE 276
with CODE M005 (4MATIC)
MODEL 212 with ENGINE 157, 272, 273, 276, 278
with CODE M005 (4MATIC)
MODEL 218 with ENGINE 157, 276, 278
with CODE M005 (4MATIC)		  
      AR61.20-P-1105EW
1.2 Remove front section of lower engine compartment paneling MODEL 204.93/98/99  
      AR61.20-P-1105CY
1.3 Remove bottom section of soundproofing at front MODEL 204.08/28 with ENGINE 642, 651
MODEL 204.09/29 with ENGINE 642
MODEL 212 with ENGINE 642, 651
with CODE M005 (4MATIC)
MODEL 218 with ENGINE 642
with CODE M005 (4MATIC)		  
      AR94.30-P-5300EW
2 Detach front wheel and tire assembly    
REFER TO MAINTENANCE   MODEL 204.08/09/28/29/38/93/98/99
MODEL 207
with CODE M005 (4MATIC)		 AP40.10-P-4050CW
REFER TO MAINTENANCE   MODEL 212, 218
with CODE M005 (4MATIC)		 AP40.10-P-4050EW
3 Remove bolt of front axle shaft (1) to wheel hub    
4 Detach right or left rpm sensor from steering knuckle and unclip electrical feed line from line bracket MODEL 204.08/09/28/29/38/93/98/99 AR42.30-P-0712CW
    MODEL 207, 212, 218
with CODE M005 (4MATIC)		 AR42.30-P-0712EW
5 Detach both stabilizer bar link rods from suspension struts IMPORTANT When removing, counterhold at the ball head bolt with internal torx.  
6 Remove track rod from steering knuckle assembly   AR46.40-P-0200-02CW
    NOTES
Turn-in steering and check for correct seating of SPECIAL TOOL the puller on the tie rod.
If seating is incorrect, damage to the steel contact ring of the tie rod occurs and this results in destruction of the tie rod.		  
    SPECIAL TOOL Thrust piece Figure
    SPECIAL TOOL Puller Figure
    SPECIAL TOOL Puller Figure
    SPECIAL TOOL Press Figure
7 Detach cross strut from steering knuckle IMPORTANT The cross struts should be detached from the steering knuckles only.  
8 Detach torque strut from front axle carrier MODEL 204.08/09/28/29/38/93/98/99
MODEL 207
with CODE M005 (4MATIC)		 AR33.15-P-0160CW
    MODEL 212, 218
with CODE M005 (4MATIC)		 AR33.15-P-0160EWX 
9 Tilt steering knuckle at side, when doing so pull front axle shaft (1) out of front axle shaft flange NOTES
Do not damage the rubber boots of the front axle shaft (1).
The front axle shaft (1) must otherwise be replaced.		  
10 Pull out front axle shaft (1) using impact extractor (02) and pulling device (03) NOTES
If the left front axle shaft (1) is seized the retaining ring (2) on the intermediate shaft (4) must be removed and then the left front axle shaft (1) can be pulled out with the intermediate shaft (4).
Otherwise the oil pan may be damaged.
IMPORTANT Absolute cleanliness is essential when working on the front axle transmission. Even minute dirt particles can prevent the front axle differential from functioning correctly.		  
    SPECIAL TOOL Extraction tool Figure
    SPECIAL TOOL Impact extractor Figure
11 Remove radial shaft sealing ring When removing right front axle shaft (1)  
12.1 Remove retaining ring from front axle shaft (1) When removing right front axle shaft (1)  
12.2 Remove retaining ring (1s) from intermediate shaft (4) When removing the left front axle shaft (1)  
INSTALLING Install     
13.1 Install retaining ring (1s) onto intermediate shaft (4) When installing the left front axle shaft (1)
IMPORTANT Apply light coating of microgrease to retaining ring (1s).
IMPORTANT Replace retaining ring (1s).		  
    Klueber Microlube GNY 202 *BR00.45-Z-1071-06A 
13.2 Install retaining ring for front axle shaft (1) When installing right front axle shaft (1)
IMPORTANT Replace retaining ring of front axle shaft (1).		  
14 Install radial shaft sealing ring When installing right front axle shaft (1)  
      AR33.30-P-0540SYZ 
    IMPORTANT Replace radial shaft seal.  
15 Insert assembly tool into radial shaft sealing ring When installing right front axle shaft (1)
NOTES
Pay attention to the splined profile of the front axle shaft (1).
Otherwise the radial shaft sealing ring will get damaged.		  
    SPECIAL TOOL Assembly tool Fig 5
16 Press in front axle shaft (1) IMPORTANT Absolute cleanliness is essential when working on the front axle transmission. Even minute dirt particles can prevent the front axle differential from functioning correctly.
IMPORTANT Before installation of the left front axle shaft (1) apply light coating of grease to toothing on intermediate shaft (4).
IMPORTANT Remove the assembly tool from the radial shaft sealing ring before fully pressing in the right front axle shaft (1).		  
17 Insert front axle shaft (1) into front axle shaft flange    
18 Install strut rod onto front axle carrier MODEL 204.08/09/28/29/38/93/98/99
MODEL 207
with CODE M005 (4MATIC)		 AR33.15-P-0160CW
    MODEL 212, 218
with CODE M005 (4MATIC)		 AR33.15-P-0160EWX 
19 Mount cross strut onto steering knuckle MODEL 204.08/09/28/29/38/93/98/99
MODEL 207
with CODE M005 (4MATIC)		 AR33.15-P-0161CW
    MODEL 212, 218
with CODE M005 (4MATIC)		 AR33.15-P-0161EW 
20 Mount tie rod onto steering knuckle   AR46.40-P-0200-02CW
    TORQUE SPECIFICATION Self-locking nut, tie rod to steering knuckle *BA46.40-P-1001-01N 
21 Attach stabilizer bar link rods to suspension struts IMPORTANT When mounting, counterhold at the ball head bolt with internal torx.  
    TORQUE SPECIFICATION Nut, link rod to suspension strut *BA32.20-P-1002-02P 
22 Mount rpm sensor at right or left onto steering knuckle and clip electrical line into line bracket MODEL 204.08/09/28/29/38/93/98/99 AR42.30-P-0712CW
    MODEL 207, 212, 218
with CODE M005 (4MATIC)		 AR42.30-P-0712EW
23 Screw in bolt of front axle shaft (1) TORQUE SPECIFICATION Screw/bolt, front axle shaft to wheel hub *BA33.30-P-1001-02H 
24 Mount front complete wheel    
REFER TO MAINTENANCE   MODEL 204.08/09/28/29/38/93/98/99
MODEL 207
with CODE M005 (4MATIC)		 AP40.10-P-4050CW
REFER TO MAINTENANCE   MODEL 212, 218
with CODE M005 (4MATIC)		 AP40.10-P-4050EW
25.1 Fit front section of lower engine compartment paneling MODEL 204.08 with ENGINE 272, 276
MODEL 204.38 with ENGINE 276
MODEL 207 with ENGINE 276
with CODE M005 (4MATIC)
MODEL 212 with ENGINE 157, 272, 273, 276, 278
with CODE M005 (4MATIC)
MODEL 218 with ENGINE 157, 276, 278
with CODE M005 (4MATIC)		  
      AR61.20-P-1105EW
25.2 Fit front section of lower engine compartment paneling MODEL 204.93/98/99  
      AR61.20-P-1105CY
25.3 Install bottom section of soundproofing at front MODEL 204.08/28 with ENGINE 642, 651
MODEL 204.09/29 with ENGINE 642
MODEL 212 with ENGINE 642, 651
with CODE M005 (4MATIC)
MODEL 218 with ENGINE 642
with CODE M005 (4MATIC)		  
      AR94.30-P-5300EW
FRONT AXLE TORSION BAR

Number Designation MODEL 204 MODEL 207
BA32.20-P-1002-02P Nut, link rod to suspension strut Nm 98 98
FRONT AXLE TORSION BAR

Number Designation MODEL 212 MODEL 218
BA32.20-P-1002-02P Nut, link rod to suspension strut Nm 98 98
FRONT AXLE SHAFT

Number Designation MODEL 204 MODEL 207
BA33.30-P-1001-02H Screw/bolt, front axle shaft to wheel hub Stage 1 Nm 160 160
Stage 2: Loosen Loosen Loosen
Stage 3 Nm 120 120
Stage 4 ∠° 90 90
FRONT AXLE SHAFT

Number Designation MODEL 212 MODEL 218
BA33.30-P-1001-02H Screw/bolt, front axle shaft to wheel hub Stage 1 Nm 160 160
Stage 2: Loosen Loosen Loosen
Stage 3 Nm 120 120
Stage 4 ∠° 90 90
TIE ROD

Number Designation MODEL 204 MODEL 207
BA46.40-P-1001-01N Self-locking nut, tie rod to steering knuckle Stage 1 Nm 50 50
Stage 2 ∠° 60 60
TIE ROD

Number Designation MODEL 212 MODEL 218
BA46.40-P-1001-01N Self-locking nut, tie rod to steering knuckle Stage 1 Nm 50 50
Stage 2 ∠° 90 90
Fig 3: Identifying Extraction Tool (221 589 04 33 00)
G09976261Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Puller (221 589 05 33 00)
G09976262Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Assembly Tool (221 589 01 98 00)
G09976263Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Impact Extractor (602 589 00 33 00)
G09976264Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Puller (221 589 00 33 00)
G09976265Courtesy of MERCEDES-BENZ USA
Fig 8: Identifying Thrust Piece (171 589 00 34 00)
G09976266Courtesy of MERCEDES-BENZ USA
Fig 9: Identifying Press (163 589 03 43 00)
G09976267Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1071-06A Klueber Microlube GNY 202 A 001 989 44 51 10
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