DRIVE AXLE
1986 DRIVE AXLES Mercedes-Benz Integral Carrier
AXLE RATIO & IDENTIFICATION
All models use integral carrier rear axle with semi-trailing arm rear suspension. To determine axle ratio, divide the number of ring gear teeth by the number of pinion gear teeth.
DESCRIPTION
Axle assembly is hypoid gear type in which centerline of drive pinion is mounted below centerline of ring gear. Axle assembly uses an integral carrier housing design. Removable rear cover permits inspection and service of differential. Some models may be equipped with limited slip differential. All adjustments, except pinion bearing preload, are performed using shims. Pinion bearing preload is set using a collapsible spacer.
REMOVAL & INSTALLATION
AXLE SHAFTS
Removal (190 Series)
Remove rear differential assembly from vehicle. Drain gear oil. Remove rear cover. Remove "C" lock and discard. Remove axle shaft from differential. Check sealing ring. Replace sealing ring (if necessary). Ensure compensating ring, inside flange, is firmly seated.
Installation (190 Series)
Install axle shaft. Install new "C" lock. Check axle shaft for end play. There should not be any end play. If there is end play, rotate "C" lock and recheck. If specification is still not correct, use a thicker "C" lock. Apply sealing compound to rear cover and install. Install rear differential assembly.
Removal (All Models Except 190 Series)
1. Drain lubricant from rear axle. Remove brake caliper and suspend with wire. Remove axle shaft-to-axle shaft flange bolt. Force axle shaft out of axle shaft flange. If additional clearance is required to aid in axle shaft removal, remove upper shock absorber mount and lower suspension arm to stop.
2. Support axle housing and remove rubber mount from body. Lower axle housing slightly. Clean housing and remove rear cover plate. Remove and discard "C" lock holding axle shaft to differential side gear. Pull shaft from gear along with spacer.
Fig. 1: Removing Axle Shaft "C" Lock
Installation (All Models Except 190 Series)
1. Face of "U" joint spider carries a stamped "R" for right or "L" for left. Ensure correct axle is used on correct side. Place old spacer ring on constant velocity joint. Slide axle shaft into differential side gear and install new "C" lock onto shaft.
2. Check end play between inner "U" joint and axle housing. There should be no end play. In addition, lock ring should still turn in groove. If necessary, install a thicker or thinner lock ring to achieve desired results.
3. Completely telescope axle shaft and install axle shaft flange. Tighten attaching nut. Mount end cover with sealing compound and tighten attaching bolts. Raise axle housing and install rubber mount to axle housing. Attach rubber mount to body.
CONSTANT VELOCITY JOINT
Removal
1. Remove axle shaft. Cut stop sleeve of constant velocity (CV) joint on beaded edge and pull sleeve from spider joint. Remove spider from hub along with 6 balls. Remove locking ring from groove in axle shaft. Press spider from shaft.
2. Pull stop sleeve and rubber sleeve from shaft. Loosen hose clamps and pull second rubber sleeve across disassembled end of axle shaft. Carefully clean joint. Inspect balls and other parts for wear or damage.
Installation
1. Slide new rubber sleeve onto shaft up to bead. Place Assembly Sleeve ( 115 589 01 63 00 ) on splines to protect against damage. Place new stop sleeve on shaft and press spider onto axle shaft. Install locking ring. Assemble spider and 6 balls using magnetic ball holders for assistance.
2. Place new sealing rings on spider and attach new protective sleeve. Insert complete axle shaft into Crimper ( 115 589 36 63 00 ) and install split supporting ring. Attach beading ring and crimp edge of sleeve while tightening nuts against stop of crimper.
3. Remove axle shaft from crimper and fill CV joint with CV joint grease (supplied with rubber sleeve repair kit). Attach rubber sleeve to stop sleeve and axle shaft with new hose clamps.
AXLE SHAFT FLANGE & BEARING
Removal (190 Series)
1. Remove rear axle shaft. Remove brake caliper and wire out of the way. Remove brake rotor. Using Puller ( 201 589 00 61 29 ), remove axle shaft flange. Remove snap ring.
2. Using a puller, remove bearing. Place axle shaft flange in a soft-jawed vise. Press bearing inner race from flange. Check flange runout. See AXLE ASSEMBLY SPECIFICATIONS .
Installation (190 Series)
Press bearing in rear axle shaft flange. Install snap ring. Ensure snap ring is seated. Install axle shaft flange. Ensure thrust washer is against bearing inner race. Install brake rotor and caliper. Install axle shaft.
Removal (All Models Except 190 Series)
1. Remove bolt and force axle shaft out of axle shaft flange. Pull axle shaft up and out of way. Support axle shaft with wire. Do not allow axle shaft to hang down. Remove brake caliper and rotor. If necessary, remove parking brake shoes.
2. Hold axle shaft flange and remove slotted nut from axle shaft flange. Remove sealing rings from support housing. Knock axle shaft flange out of support housing. Remove bearing inner race along with spacer sleeve.
3. Remove outer sealing ring from support housing. Remove outer bearing outer race from support housing. Remove inner bearing outer race from support housing. Remove outer bearing inner race from axle shaft flange.
Fig. 2: Checking Axle Shaft Flange End Play
Installation (All Models Except 190 Series)
1. Ensure axle shaft flanges are installed on correct sides. Right flange is marked with "R" and left flange is marked with "L". Press outer bearing inner race onto axle shaft flange. Install both outer bearing races in support housing.
2. Coat seat for outer sealing ring on support housing with sealing compound and install seal. Ensure seal rests straight against chamfer at bottom of housing. Fill cavity between bearing races in support housing with grease.
3. Attach new spacer sleeve to axle shaft flange and install into carrier housing. Attach inner bearing inner race onto axle shaft. Fill new sealing ring with anti-friction grease and coat outer edge with sealing compound. Press inner race and sealing ring into housing. Install seal running ring and install new slot nut.
Fig. 3: Exploded View of Drive Axle Assembly (Except 190 Series)
4. Attach dial indicator to support housing and adjust end play of axle shaft flange while rotating axle shaft flange back and forth. If slot nut is overtightened, reducing end play to zero, install new spacer sleeve and retighten slot nut.
5. Lock slot nut in place by bending in axle shaft flange at 2 points. Install axle shaft and brake components. Bleed brake system.
PINION FLANGE & SEAL
Removal (All Models Except 190 Series)
1. Remove exhaust system and shield (if necessary). Loosen clamping nut and unscrew drive shaft intermediate bearing from frame. On 3-piece drive shaft, loosen front clamping nut only. Remove drive shaft from axle and push forward out of center support.
2. Ensure axle shafts are horizontal and that brakes are not dragging. Measure and record torque required to rotate entire rear axle assembly. Attach holding wrench to flange and remove slotted nut.
3. Pull flange from pinion using puller (if necessary). Pry seal out of housing using a screwdriver. Check running surface of seal on flange. Replace flange if surface is worn.
Installation (All Models Except 190 Series)
1. Coat outside diameter of new seal with gear oil. Install seal into axle housing using a seal installer. Attach flange and carefully tighten slotted nut until rotating torque for rear axle is the same as measured before removal. DO NOT overtighten or a new collapsible spacer will have to be installed on pinion. Peen nut if crush nut is used.
2. Reconnect drive shaft and lightly tighten drive shaft intermediate bearing. Fill axle housing with oil. Lower vehicle and move back and forth several times. Tighten clamping nut drive shaft intermediate bearing. Reinstall shield and exhaust system (if removed).
Removal (190 Series)
1. Remove exhaust shield. Loosen clamping nut and unscrew drive shaft intermediate bearing on frame floor. Remove drive shaft from flange on rear axle and push forward from center position.
2. Tie drive shaft with wire to frame floor. Measure and record rotating torque of entire rear axle drive. When measuring rotating torque, ensure rear axle shafts are approximately horizontal. Ensure brake pads are not rubbing against brake disks or parking brake shoes against drum.
3. Position Holding Wrench ( 040 ) on universal flange and loosen 12-point collar. Loosen, but DO NOT remove, collar nut with crush lock. Remove universal flange from drive pinion using puller.
4. Remove radial seal from rear axle housing using a screwdriver. See Fig. 4 . Check running surface of seal on universal flange. Replace universal flange if running surface is worn out.
Fig. 4: Removing Axle Flange
Installation (190 Series)
1. To install, reverse removal procedure. Install seal. Mount universal flange and carefully tighten with a new 12-point collar nut until measured rotating torque is attained.
2. Tighten collar nut to at least 133 ft. lbs. (180 N.m). If this minimum tightening is not attained, replace elastic spacing sleeve.
AXLE ASSEMBLY
Removal (All Models Except 190 Series)
1. Drain oil from rear axle. On vehicles without starting torque compensation, remove right brake caliper and suspend out of way. On vehicles with starting torque compensation, disconnect brake control cable. Loosen rubber bearing from frame floor and rear center piece from rear axle carrier.
2. Disconnect axle shafts from axle shaft flange on both sides. If necessary, remove exhaust system and shield (if necessary). Loosen clamping nut and unscrew drive shaft intermediate bearing on frame.
3. On 3-piece drive shaft, loosen front clamping nut only. Disconnect drive shaft and push forward out of way. On models equipped with anti-lock brake system, remove RPM sensor. Support axle assembly with jack and holding fixture.
4. Unbolt rear rubber mounting on frame floor. Fold back rubber mat in trunk and remove rubber plugs. Unbolt axle housing from rear axle carrier.
5. Lower rear axle and remove along with axle drive shafts. Use care not to let axle drive shafts drop. Unbolt rubber mounting from housing and replace if worn or damaged.