Drive Axles, Bearings and Joints: Service and Repair

Remove/install Complete Rear Axle










DANGER
- Risk of death. Death may result if vehicle slips or topples from the lifting platform.
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

CAUTION:
- While working on the rear axle care must be taken to ensure that the surface of all aluminum components do not get any scratches, cracks and notches. Otherwise the service life of the parts will be affected
- Notes on self-locking nuts and bolts


1 Remove rear wheels
2 Remove exhaust system as of flange connection
3 Unhook brake cables (1) on automatic cable slack adjuster (2) of parking brake
4 Unscrew bolts of propeller shaft intermediate bearing (3)
5 Detach rear propeller shaft assembly (4) from rear axle center assembly.

NOTE:
- Flexible disk remains on propeller shaft.
- Installation: Attach rear propeller shaft to rear axle center assembly.

6 Slacken flexible coupling fitted sleeves on flange.

NOTE: Put propeller shaft to one side and tie up

7 Disconnect right rear brake pad contact sensor connector (S 10/4x1)
8 Detach cover of fuel pump assembly (5)
9 Undo plug-in connection for left (1-6/3x1) and right (1-6/4x1) wheel speed sensors.
10 Detach cover of spring link (6)

NOTE: To do this, pull pin out of body-bound rivet and remove body-bound rivet from spring link and remove cover of spring link (6).

11 Detach suspension strut (7) from spring link
12 Detach control rod of level sensor (8) from both spring links

DANGER
- Risk of poisoning from swallowing brake fluid. Risk of injury from brake fluid coming into contact with skin and eyes.
- Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

13 Detach brake line from brake hose (9) and plug openings

NOTE:
- When slackening or tightening the brake line at brake hose (9), ensure that the fitting is not turned. Use an open-end wrench to counterhold at the two flats of the brake hose (51).
- Seal off line connections immediately with plugs. The brake fluid reservoir must not be allowed to empty completely.

CAUTION: See Brake fluid notes

NOTE: Installation: The brake hose (9) must not be twisted after tightening.

CAUTION: See notes on installing brake hoses

14 Install protective disk
15 Use assembly attachment, pit hoist or floor jack beneath rear axle center assembly to support rear axle (10).
16 Detach front rear axle mount bolts (11c) and rear rear axle mount bolls (11d)

NOTE:
- Installation: recut thread on frame floor with tap.
- Installation: Tighten bolts in accordance with tightening angle.

17 Carefully lower the rear axle (10)

NOTE: In the process do not trap any brake cables (1) and lines.

18 Check rear axle (10) for damage and if necessary replace parts
19 Install in the reverse order
20 Check rear axle center assembly oil level, adjust to correct level if necessary.

NOTE: Since 4.11.2001 a fully synthetic oil has been used in the rear axle gear.

CAUTION: Premixing of old and new oils should be avoided due to the better fuel economy.

21 Bleed brake system.
22 Check vehicle level at rear axle, correct if necessary.
23 Check the headlamp adjustment and correct if necessary.