Installation

Installation





Attention! Rear axle shafts are provided with oil return threads (twist) on running surface of radial sealing ring. which are different for left and right. For identification, the face of the inside joint is provided with an electrically written "R" for the righthand side and an "L" for the lefthand side. The oil return feed thread or the identification is in place up to September 1979 on models 107.023/024/043/044, 116.028/029/03 and up to February 1981 on models 107.022/042 and 123.




10 Refinish oil return feed thread, if required, with emery cloth (grit 180) at an angle of approx. 20° and for a length of 20-30 mm.


Note: When installing a radial sealing ring with alternating feed thread, refinishing of oil return feed thread is not necessary. If a rear axle shaft is installed without oil return feed thread, make sure that a radial sealing ring with alternate feed thread is installed.





11 If a new rear axle shaft is installed, place the previously removed spacing ring (11) on inner synchromesh joint.




12 Introduce complete rear axle shaft into side gear and insert new locking ring into groove of inner synchromesh joint.


Attention!
If the rear axle shaft cannot be introduced into differential housing up to contact surface, contract both joints first. Then apply light blows with a plastic hammer against outer spider to knock rear axle shaft against contact surface of differential housing. Do not apply hammer blows against stop sleeve.
Do not permit rear axle shaft to drop or to bend sharply, since this will damage housing for synchromesh joint and result in leaks.




13 Check end play between inner spider and differential housing. There should be no noticeable end play; the locking ring (26) should just barely turn in groove. If required, use thicker or thinner spacing ring (27).


Attention! Renew locking ring after one-time use.




14 Telescope rear axle shaft completely and insert into rear axle shaft flange (78) by means of assembly tool (O5a-O5c).




15 On version 1, tighten hex. screw M 12 to 95 Nm. On version 2, mount hex. screw M 8 with clamping disc and spacing sleeve and tighten to 30 Nm.


Attention! Renew clamping disc after one-time use. Provide clamping disc with oil in range of screw head. Pay attention to correct length of spacing sleeve and hex. screw.




Note: In the event of complaints about clicking noises, exchange hex. screw M 12 with a thick washer for a hex. screw M 8 with pertinent spacing sleeve and clamping disc. To reduce threads, screw a threaded bushing (79c) into rear axle shaft by means of self-made tool. Tightening torque of threaded bushing 30 Nm.

79 Hex. screw
79a Clamping disc
79b Spacing sleeve
79c Threaded bushing

Detail at left:
Repair solution

Detail at right:
Standard version




Attention! When installing a new or a reconditioned rear axle shaft with one-piece protective sleeve on outer joint, check semi-trailing arm in operating range of protective sleeve for weld residue. Remove weld beads, since otherwise the protective sleeve may be chafed through. Also check installed rear axle shaft for wiping noises. If wiping noises are heard when rotating rear axle shaft, refinish wheel carrier in operating range of protective sleeve (arrows).


16 Mount rear axle end cover with sealing compound and tighten hex. screws to 45 Nm.


Model 107, 114, 115, 116 and 123





17 Lift rear axle housing and screw rubber bearing to frame floor. Tighten hex. screws (version 1) to 25 Nm or self-locking hex. screws (version 2) to 30 Nm.

Attention! Use self-locking hex. screws only once.

Model 126




18 Lift rear axle center piece up to frame floor and attach rubber bearing to frame floor. Tightening torque of self-locking hex. screws of version 1 or hex. screws of (version 2) 30 Nm.

19 In the event of repairs, replace version 1 by version 2.

Version 1:

Self-locking hex. screws (arrow) and holder with nut without lock.

Attention! Always renew holder of version 2 after one-time use on principle.

Version 2:

Hex. screws without lock and holder with self-locking nuts (arrow).




20 On rear axles with starting torque compensation, if removed:
Mount brake hose.
Bleed brake system.

21 Remove vehicle jack or pitlift and top.




22 On rear axles without starting torque compensation mount caliper with new locking plate or selflocking hex bolts. Tightening torque of hex bolts 90 Nm.




23 Fill rear axle housing with oil up to level of filler hole.