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

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












DANGER:
- 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 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 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 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.

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
- Notes on self-locking nuts and bolts

NOTE:
- Read notes on ABC-suspension
- Read notes on handling brake fluid

1 Raise vehicle.

NOTE: Position the lifting platform arms so that the bolts (5/1) of rear reinforcement brace (5) are accessible.

2 Deactivate SBC system using STAR DIAGNOSIS.
- Diagnosis system STAR DIAGNOSIS

3 Remove rear wheels.
4 Remove exhaust system
5 Remove heat shield under propeller shaft
6 Detach rear propeller shaft (106) from rear axle center assembly.

NOTE: Flexible disk remains on propeller shaft.

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

NOTE: Installation: Assemble propeller shaft in correct order.

9 Unhook brake cables (112a)
10 Remove left heat shield (2a) and right heat shield (2b)
11 Unplug right rear rpm sensor/brake wear indicator connector (X62/2)
12 Unplug left rear rpm sensor/brake wear indicator connector (X62/1)
13 Open bleed screws (57) and depressurize suspension struts (41)

NOTE: The engine must be shut off for at least 5 minutes.

CAUTION: Carefully open bleed screws (57) so that hydraulic fluid can flow out slowly.

NOTE: Connect hose and collect hydraulic fluid in a suitable container.

14 Separate quick-release fitting (41 a) of hydraulic line

CAUTION: Ensure that no dirt gets into the open quick-release fitting (41a).

NOTE:
- Check protective cap (41 b) and replace if findings are negative.
- Installation: Ensure that the quick-release fitting engages properly.

15 Pull hydraulic line with grommet out of bracket (arrow) and place to the side
16 Detach spring strut (41) from spring link
17 Disconnect level sensor connector, remove tie strap on feed line
18 Remove level sensor control rod (122a) from spring links
19 Unscrew brake line from brake hose (111e)

CAUTION: Seal off line connections immediately with plugs. Do not allow all of the fluid to drain from the brake fluid reservoir.

NOTE: Installation:The brake hose (111e) must not be twisted after being tightened.

CAUTION: Read Notes on installing brake hoses

20 Mounting guard plates
21 Support rear axle (1) with transmission jack and transmission platform at rear axle center assembly and lash securely
22 Unscrew bolts (1c, 1d) of rear axle mount
23 Lower rear axle (1)

NOTE: Make sure that when doing so no brake control cables or lines are trapped.

24 Check rear axle (1) for damage, and replace damaged parts if necessary
25 Install in the reverse order
26 Check oil level in rear axle center assembly and correct if necessary

NOTE: Premixing old universal hypoid transmission oil and new FE hypoid transmission oil should be avoided due to the better fuel economy.

27 Activate SBC brake system using STAR DIAGNOSIS.
28 Bleed brake system with STAR DIAGNOSIS
29 Set brake pad application using STAR DIAGNOSIS

DANGER
- Risk of accident as vehicle may start off by itself with the engine running. Risk of injury as working around the engine during startup or while running may result In contusions and burns
- Secure vehicle to prevent it from moving. Wear dosed and snug-fitting work clothes. Do not grasp hot or rotating parts.

30 Fill and bleed ABC system
31 Perform chassis alignment check