Drive Axles, Bearings and Joints: Service and Repair

AR35.10-P-0010T Remove/Install Complete Rear Axle

Shown On Model 211 With Airmatic:

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.
- Risk of injury Body parts may become jammed or crushed. Risk of injury Skin and eyes may be injured due to brake fluid spraying out at high pressure when working on the SBC brake system
- Deactivate SBC brake system using STAR DIAGNOSIS.
- 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.

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

NOTE: See notes on handling brake fluid

1 Empty air springs (6i) completely
- With Airmatic code (489a)

CAUTION: Installation: The filling process of the air springs should be observed otherwise these will be destroyed.

DANGER:
- Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury with caustic burns to eyes and skin from battery electrolyte or from handling damaged lead-acid batteries.
- No fire, sparks, naked flames or smoking.
- Wear acid-resistant gloves, clothing and goggles. Pour battery electrolyte only into suitable and appropriately marked containers.

2 Disconnect ground cable of battery

CAUTION:
- Do not connect quiescent current retention device.

3.1 Remove rear muffler
3.2 Remove exhaust system as of flange connection
4 Remove underbody paneling

NOTE: Only left and right part.

5 Unhook rear brake cables at cable slack adjuster
6 Detach propeller shaft (106) from rear axle center assembly (50)

NOTE: Flexible disk remains on propeller shaft.

7 Slacken flexible coupling fitted sleeves on flange.
8 Unscrew bolts of propeller shaft intermediate bearing (106a) and remove rear part of propeller shaft (106)

NOTE: Installation: Assemble propeller shaft in correct order. Tighten flexible coupling on rear axle center assembly before tightening bolts on propeller shaft intermediate bearing

9 Remove rear wheels.
10 Unscrew left and right rear brake hose (51) from brake line

CAUTION:
- Seal off line connections immediately with plugs. The brake fluid reservoir must not empty completely.
- Installation: The brake hose (51) must not be twisted after being tightened.
- See notes on installing brake hoses

11 Remove fender liner of rear fender
- With Airmatic code (489a)

12 Disconnect electrical connectors of brake and chassis components at the rear axle
- With Airmatic code (489a)

13 Remove rear rpm sensors (L6/3, L6/4) from the wheel carriers
- Except Airmatic code (489a)

NOTE: Unclip electrical feed lines of rpm sensors from all retaining clamps and tie rpm sensors to one side.

14 Disconnect electrical connector of the right rear brake pad contact sensor (S10/4)
- Except Airmatic code (489a)

15 Unscrew electrical feed line (1) of the right rear brake pad contact sensor (S10/4) from floating brake caliper
- Except Airmatic code (489a)

NOTE: Unclip electrical feed line of the right rear brake pad contact sensor from retaining clamps and tie up to one side.

16 Unclip left and right air spring (6i) using assembly lever on frame floor
- With Airmatic code (489a)

NOTE: Installation: Push air springs onto retaining clip on frame floor until they latch audibly. The air spring must be aligned straight and must not be kinked.

17 Unscrew left and right dampers (6j) from spring links
18 Remove left and right rear springs
- Except Airmatic code (489a)

19 Pinch off filler hose (17) of fuel tank

DANGER:
- Risk of explosion if ignition takes place, risk of poisoning caused by inhaling fuel vapors or swallowing fuel, as well as risk of injury to skin and eyes exposed to fuel.
- No fire, sparks, naked flames or smoking.
- Pour fuels only into suitable and appropriately marked containers.
- Wear protective clothing when handling fuel.

20 Disconnect filler hose (17) of fuel tank at filler neck (17a)

CAUTION: Collect fuel which runs out in a suitable container.

- Check filler hose and hose clamps, if necessary empty fuel tank and replace filler hose.

21 Mount guard plates (01)
22 Lower rear axle
23 Replace retaining clips of air springs

Inspect
24 Check rear axle for damage, replace damaged parts
25 Check condition of air springs
- With Airmatic code (489a)

26 Install in the reverse order
27 Check oil level in rear axle center assembly and correct if necessary
28 Activate SBC brake system using STAR DIAGNOSIS.
29 Use STAR DIAGNOSIS to move brake pads toward brake disks
30 Perform basic programming
31 Perform chassis alignment check.