Output Shaft: Service and Repair

Removal and installation of connection flange on rear axle shaft (rear axle center piece installed)






Special Tools






Note: Clean rear axle housing thoroughly in area of bearing cap to prevent dirt from getting into rear axle housing.

Removal, installation






1. Drain oil in rear axle, fill (arrows).

Installation note: Fill with hypoid gear oil up to bottom edge of oil fill hole.






2. Remove rear axle shaft at connection flange, install.

Installation note: Renew retaining bolts (28m) and washers (28n). Retaining bolts M10 = 70 Nm, oiled on threads and bolt head contact surface, M12 = 125-145 Nm. Torque wrench 001 589 87 21 00.






3. Press rear axle shaft together in axial direction and tie to rear spring with wire.






4. Support rear axle center piece.






5. Screw rear self-locking serrated bolt (57d) out of end cover (57), screw in and remove together with rubber supports (57a, 57b), install.

Installation note: Renew self-locking serrated bolts (57d), 110 Nm. Check rubber supports (57a, 57b) for wear, renew, if required.






6. Lower rear axle center piece, raise.
7. Remove end cover (57), install.

Installation note: Clean sealing surfaces on end cover and on rear axle housing and coat with sealant. Hex. head bolts, strength class 8.8 = 45 Nm, 10.9 = 50 Nm.






8. Pull retaining ring (30) oft of connection flange with pliers or suitable hook, install.

Installation note: Renew retaining ring (30).






9. Pull connection flange (33) together with shim (31) out of rear axle shaft gear, insert.


Installation note: Check running surface for radial shaft seal on connection flange, renew connection flange if required when running surface is worn heavily.






10. Check axial play between connection flange and rear axle shaft gear.

Installation note: It should not be possible to feel any axial play, however it should still be possible to turn the retaining ring in the groove. Install thicker shim (31) if required (see table).










Note: On vehicles with ASD adjustment of the axial play is not required.

11. Install in opposite order.