AR33.10-P-0100N Remove/Install Front Axle

AR33.10-P-0100N Removing and Installing Front Axle
- with CODE (487) Active body control (ABC) [model 220]

Shown On Model 220:

DANGER
- Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning from swallowing hydraulic fluid.
- Release the pressure in the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.
- 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.
- 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: See notes on self-locking nuts and bolts

1 Deactivate SBC brake system
2 Extract the hydraulic fluid from the power steering pump's reservoir
3 Turn steering wheel to center position (front wheels in straight ahead position) and fix in place

CAUTION:
- On vehicles with easy entry/exit, this function must be disabled to prevent damaging the windshield, refer to: See Operator's manual.
- The steering wheel must not be turned with the steering coupling (25) detached otherwise the contact spiral will be destroyed.

4 Remove the front wheels
5 Install guard plates for brake caliper dust shields
6 Disconnect right front axle electrical distributor connector, major assembly compartment (X62/6) and left front axle electrical distributor connector, major assembly compartment (X62/7)
7 Disconnect connector of left front brake pad contact sensor (S10/1x1) and connector of right front brake pad contact sensor (S10/2x1)
8 Disconnect brake line from hose (39) and seal off openings

NOTE:
- Seal connections immediately with plugs. The brake fluid reservoir must not empty completely.
- When loosening or tightening the brake line on the brake hose (39), take care not to twist the bracket. Counterhold using an open wrench on the two flats on the brake hose (39).

CAUTION:
- See Brake fluid notes
- See notes on installing brake hoses
- Installation: The brake hose (39) must not be twisted after tightening (risk of cracking).

9 Detach lower engine compartment paneling
10 Remove front diagonal struts
- Model 230

11 Dismount bracket of pressure line (54a, 54b) from front axle carrier
- Model 215, 220

12 Remove heat shield (2c) and bracket (1n)
- Model 230

13 Detach pressure supply valve unit (52) from rear right of front axle carrier
- Model 215, 220

NOTE: Tie up pressure supply valve unit (52) to the side.

14 Dismount bracket of pressure line (54c) of pressure supply valve unit (52) from front axle carrier

NOTE: Tie up pressure line to the side

15 Press guide joint (8) out of steering knuckle (5)
16 Unscrew bolt (25a) of steering coupling (25) out of lower steering shaft (80a)

CAUTION: Installation: Replace locking plate (25f) with self-locking nut.

17 Place a suitable tool in the hole of the steering coupling (25) or in the hole of the lower steering shaft (80a) and pull out lower steering shaft (80a) from steering coupling (25) toward top

CAUTION: Do not counterhold the lower steering shaft (80a) at the rubber boot or the temperature-resistant plastic disk. Do not use force (hammer blows, excessive leverage) as the lower steering shaft is sensitive to lateral forces.

NOTE: Installation: Insert lower steering shaft (80a) up to the stop into the steering coupling (25), at the same time observe studs of the steering coupling (25),and groove of the lower steering shaft (80a) (arrows).

18 Unplug connector at speed-sensitive power steering (3)
19.1 Unscrew bolts (40c) from spring strut (40)
- Model 215, 220

NOTE: Installation: After tightening, the bolt (40c) must be flush with the suspension strut (40) or be slightly recessed.

19.2 Unscrew nut of suspension strut (40) on spring link and press suspension strut (40) out of spring link
- Model 230

20 Unscrew bolts (1g) and dismount engine mount from front axle carrier (1)
21.1 Raise engine
21.2 Put engine support bracket in place and secure engine
22 Support front axle carrier (1)

CAUTION: When working on the front axle, take care to prevent leaving scratches, cracks or notches in the surfaces of the aluminum components. Otherwise the service life of the parts will be reduced.

23 Unscrew bolts (1) from front axle carrier (1).

CAUTION:
- The screws (1f) are self-tapping. Pay attention to the following points
- Never recut thread (1f) in longitudinal member
- Replace bolts (1f)
- Only use original bolts (4 ea.)
- Do not position bolts (1f) at an angle when screwing in.
- Do not use an impact wrench
- Pay attention to tightening torque.

NOTE: Installation:
- Model 215, 220: Before tightening the bolt (1f), center the front axle carrier (1) with drift (a, diameter: 14.8 mm). After this, insert rubber plugs.
- Model 230: Before tightening the bolts (1f), center the front axle carrier (1).

24 Detach high-pressure expansion hose (30i) and return line (30f)from steering gear

CAUTION: If necessary lower the front axle so that the lines are not under tension in order to prevent irreparable damage. Seal line connections.

25 Remove heat shield at front axle carrier
- Model 215, 220

26 Lower front axle
27 Remove upper transverse control arm (6)
- If necessary

28 Remove suspension strut (40)
- If necessary

29 Check front axle for damage, replace damaged parts
30 Install in the reverse order

NOTE: Installation: Tighten nuts and bolts of chassis components only in curb condition.

31 Filling and bleeding power steering pump
32 Activate SBC brake system using STAR DIAGNOSIS
- Model 230

DANGER:
- Risk of accident when the vehicle is first operated following repair work due to inadequate braking effect the first time the service brake is applied.
- Depress brake pedal several times before operating vehicle until pressure is built up an maintained in the brake system

33 Bleed brake system on front axle
34 Set brake pad application using STAR DIAGNOSIS
- Model 230

35 Perform chassis alignment check.