35 Rear Axle

Maintenance Jobs - 1986 through 1993

• 3501 - Rear axle oil change
• 3510 - Rear axle, checking, correcting oil level
• 3565 - Rear axle mount, adjusting limiting stop

Maintenance Jobs - 1994 through 1995

• 3211 - Level control, ADS, ASD fluid level
• 3353 - Checking front axle ball joints
• 3355 - Checking ball joints using special tool
• 3501 - Rear axle oil change

Service Information

• Service Intro - Model Year 1992, Model 124 (USA), Introduction into Service
• Service Intro - Model Year 1992, 400E/500E, Introduction into Service

Additional Information

• Bad Wheel Bearing?
• Trailing Arm Bushing Replacement

---

Rear axle

• 35-010 - Removing and installation of rear axle complete
• 35-040 - Removal and installation of front and rear rubber mounts of rear suspension (See TechMods)
• 35-050 - Removal and installation of rear rubber mounts for center assembly mounting in rear axle bracket (See TechMods)

Wheel location system

• 35-110 - Removing and installation of camber strut (See TechMods)
• 35-111 - Removing and installation of torque strut (See TechMods)
• 35-112 - Removing and installation of tie rod, replacement of rubber mount (See TechMods)
• 35-113 - Removing and installation of thrust arm (See TechMods)
• 35-114 - Removing and installation of spring link, replacement of rubber mount (See TechMods)
• 35-115 - Removing and installation of wheel carrier
• 35-116 - Replacement of supporting joint on wheel carrier (wheel carrier installed)
• 35-130 - Removal and installation of rear axle shaft flange with angular ball bearing

Rear axle center assembly

• 35-520 - Removal and installation of rear axle center assembly (See TechMods)
  • - Select model... A. Model 201 B. Model 124
• 35-530 - Replacement of radial sealing ring on bevel drive pinion (rear axle center assembly installed)
• 35-540 - Replacement of radial sealing ring on connecting flange of rear axle shaft
  • - Select size... A. Rear axle center assembly with 168 mm dia crown wheel B. Rear axle center assembly with 185 mm dia crown wheel C. Rear axle center assembly with 210 mm dia crown wheel
• 35-620 - Removal and installation of rear axle shafts (See TechMods)
• 35-660 - Replacement of rubber cup seal on rear axle shaft (See TechMods)
• 35-670 - Removal and installation of connecting flange of rear axle shaft

- with 185 mm dia ring gear

• M18 - Contents
• 35-0550C - A1 Dismantling and assembling rear axle center assembly, adjusting gear assembly (185 mm dia)
• 35-0560A - M2 Disassembling and assembling differential
• 35-519 - Bleeding the ASD hydraulic system
• 35-519C - K3 Bleeding the ASD hydraulic system (Model W129, W202)
• 35-0545C - F4 Repairing ASD ring cylinder (185 mm dia)
• 35-0560C - E4 Dismantling and assembling ASD differential
• D8 - Testing and repair work
  • D8 thru M9 ... D8 Clamping rear axle center assembly in assembly frame G8 Removal and installation of locking ring on connecting flange H8 Pressing out and pressing in radial seal ring on side of rear axle housing K8 Pressing out and pressing in radial seal ring on side of rear axle housing O8 Removal and installation of radial seal ring on side of rear axle housing A9 Removing and installing ASD hydraulic pipe on rear axle center assembly B9 Removing and installing ring cylinder D9 Removing right-hand locking ring from rear axle housing using spreader K9 Removing tapered roller bearing outer races from rear axle housing L9 Removing and installing differential at rear axle housing M9 Removing tapered roller bearing inner races from differential
  • N9 thru C11 ... N9 Loosening and unscrewing twelve-point collared nut on joint flange O9 Removing joint flange P9 Pressing drive pinion out of rear axle housing A10 Pressing radial seal out of rear axle housing B10 Removing tapered roller bearing ouer races from rear axle housing C10 Removing ABS from drive pinion D10 Removing tapered roller bearing inner race from drive pinion E10 Checking drive pinion and crown wheel for pairing number F10 Pressing tapered roller bearing inner race onto drive pinion G10 Pressing ABS gear onto drive pinion H10 Calculating shim and installing in rear axle housing O10 Pulling tapered roller bearing outer races into rear axle housing P10 Installing spacer sleeve with bearing washers on both sides on drive pinion A11 Installing drive pinion in rear axle housing B11 Clipping thrust washer onto tapered roller bearing inner race C11 Install tapered roller bearing inner race on drive pinion & press w/ radial seal ring
  • E11 thru P13... E11 Adjusting friction torque of drive pinion bearing L11 Checking adjustment dimension of drive pinion P11 Locking twelve-point or hexagon collared nut on drive pinion propeller flange A12 Installaing crown wheel on differential G12 Pressing tapered roller bearing inner races onto differential H12 Installing left-hand tapered roller bearing outer race in rear axle housing J12 Installing left-hand locking ring L12 Pretensioning (spreading) reear axle housing using spreader A13 Installing right-hand locking ring B13 Measuring expanded dimension (expansion) of rear axle housing E13 Measuring gear backlash beween drive pinion and crown wheel & correcting H13 Checking locking ring for correct seating J13 Installing oil deflector in rear axle housing K13 Checking and adjusting axial play of connecting flange L13 Attaching end cover N13 Clamping differential housing O13 Driving roll pin and differential pin out and in P13 Removing differential bevel gears and differential side gears
  • A14 thru K15... A14 Installing differential side gears and differential bevel gears C14 Checking friction torque of differential J14 Pulling off and pressing on grooved ball bearing connecting flange L14 Repairing ring cylinder B15 Driving out and driving in ASD differential pin and roll pin D15 Removing and installing differential bevel gears with spherical washers F15 Removing and installing differential side gears with friction washers K15 Checking friction torque of ASD differential
• N15 - Function descriptions, model/equipment combinations
• N16 - Special tools ??
• A17 - Technical modifications
  • - Select mod... C17 Tapped hole of speed sensor on rear axle housing moved D17 Radial seal ring on side of rear axle housing & connecting flange modified G17 Routing of ASD ring cylinder and hydraulic pipe modified H17 Radial seal ring and joint flange on drive pinion modified M17 Integrated thrust washer on tapered roller bearing inner race N17 Gear sets ground O17 Gear sets ground P17 Imbalance on joint flange drive pinion reduced A18 Tightening torque of ring gear screws reduced B18 Connecting flange with centering C18 Balancing of differential housing D18 Balancing of differential housing E18 Modified ASD hydraulic unit F18 Modified ASD hydraulic unit
• G18 - Shop made tools
  • - Select tool... H18 Press-on sleeve, drive pinion inner race J18 Press-on sleeve for ABS gear on drive pinion K18 Chisel for collar nut on joint flange
• L18 - Modification note

- with 210 mm dia ring gear

• M18 - Contents
• 35-0550D - A1 Dismantling and assembling rear axle center assembly, adjusting gear assembly (210 mm dia)
• 35-0560A - M2 Disassembling and assembling differential
• 35-519 - Bleeding the ASD hydraulic system
• 35-519A - G3 Bleeding the ASD hydraulic system (W140)
• 35-519C - K3 Bleeding the ASD hydraulic system (Model W129, W202)
• 35-0545D - N3 Repairing ASD ring cylinder (210 mm dia)
• 35-0560C - E4 Dismantling and assembling ASD differential
• M10 - Testing and repair work
  • M10 thru O13 ... M10 Pressing tapered roller bearing inner race onto pinion N10 Pressing ABS gear onto drive pinion O10 Calculating shim and installing in rear axle housing F11 Pulling tapered roller bearing outer races into rear axle housing G11 Installing spacer sleeve with bearing washers on drive pinion H11 Installing drive pinion in rear axle housing J11 Clipping thrust washer onto tapered roller bearing inner race K11 Install tapered roller bearing inner race on drive pinion + radial seal ring M11 Adjusting friction torque of drive pinion bearing C12 Checking adjustment dimension of drive pinion F12 Locking 12-point or hes collared nut on drive pinion propeller flange G12 Fitting ring gear on diff M12 Pressing tapered roller bearing inner races onto diff N12 Pressing tapered roller bearing outer races outof/onto bearing cover O12 Pressing tapered roller bearing outer races outof/onto bearing cover P12 Pressing radial seal ring ino bearing cover A13 Pressing radial seal ring ino bearing cover B13 Pressing radial seal ring ino bearing cover C13 Pushing side bearing covers into rear axle housing + installing diff gear F13 Preloading rear axle housing and measuring expanded dimension J13 Measuring gear backlash btwn pinion and crown wheel and correcting M13 Pulling off and pressing on grooved ball bearing connecting flange O13 Detaching and attaching ASD hydraulic pipe on rear axle center assembly
  • P13 thru J13 ... P13 Removal and installation of locking ring on connecting flange A14 Checking and adjusting axial play of connecting flange B14 Attaching end cover D14 Clamping rear axle center assembly in assembly frame G14 Detaching side bearing covers H14 Knocking radial seal ring out of bearing cover K14 Removing tapered roller bearing inner races from diff L14 Loosening and unscrewing 12-point collared nut on joint flange M14 Removing joint flange N14 Pressing drive pinion out of rear axle housing O14 Pressing radial seal out of rear axle housing P14 Removing tapered roller bearing outer races from rear axle housing A15 Removing ABS gear from drive pinion B15 Removing tapered roller bearing inner races from drive pinion C15 Checking drive pinion and crown wheel for pairing number D15 Clamping diff housing E15 Driving roll pin and differential pin out and in F15 Removing diff bevel gears and differential side gears G15 Installing diff side gears and bevel gears J15 Checking friction torque of diff
  • P15 thru N16 ... P15 Repair ring cylinder E16 Driving out and driving in ASD differential pin and roll pin G16 Removal and installing differential bevel gears with sperical washers J16 Removing and installing differential side gears with friction washers N16 Checking friction torque of ASD differential
• A17 - Features, installation survey for rear axle center assemblies (210 mm dia)
• H17 - Technical modifications
  • - Select mod... J17 Gear sets ground K17 Integrated thrust washer on tapered roller bearing inner race L17 Radial seal ring and joint flange on drive pinion is modified P17 Imbalance on joint flange drive pinion reduced A18 Connecting flange with centering B18 Tapped hole of speed sensor on rear axle housing moved C18 Balancing of differential housing D18 Balancing of differential housing E18 Modified ASD hydraulic unit F18 Modified ASD hydraulic unit
• G18 - Shop made tools
  • - Select tool... H18 Press-on sleeve, drive pinion inner race J18 Press-on sleeve for ABS gear on drive pinion K18 Chisel for collar nut on joint flange
• L18 - Modification note
  
• Technical modifications - Rear axle - wheel location system and drive
• Program Repairs
  • Complaint/type of modification...
    Noise on rear axle Model 201 Standardization of rear axle housing for Model 124 and 201 ABS speed sensor with modular design Additional dust cover for rear axle wheel bearing on vehicles used on bad roads Hole circle diameter on rear axle center assembly joint flange changed from 80 mm to 90 mm

---