453 — fortwo / forfour (2014-2024) — Suspension & Axles¶

Workshop and reference excerpts for 453 — fortwo / forfour (2014-2024) in the Suspension & Axles system.

60 excerpts from 1 sources.

2014-2024 Smart Fortwo 453 Workshop Manual.pdf¶

Bolt (with Code (K13) Diesel¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 586 · Applies to: 453 · AR: AR33.30-P-0620FG, AR26.10-P-0031FF, AR61.20-P-1105FF, AR49.10-P-7170FF, AR20.00-P-1142FG (+4 more)

25 Bolt (with Code (K13) Diesel particulate filter) 26 Pressure differential sensor (DPF) connector (with Code (K13) Diesel particulate filter) B19/9x1 Temperature sensor connector upstream diesel particulate filter (with Code (K13) Diesel particulate filter) B19/11x1 Temperature sensor connector upstream turbocharger (with Code (K13) Diesel particulate filter) B28/8 Pressure differential sensor (DPF) (with Code (K13) Diesel particulate filter) P01.10-2838-05 Remove/install

1 Remove front drive shafts AR33.30-P-0620FG 2 Remove lower transmission bearing AR26.10-P-0031FF 3 Detach lower engine compartment paneling AR61.20-P-1105FF 4.1 Detach slave cylinder at transmission Only for transmission 717.473 AR25.20-P-0150-01FF *BA25.20-P-1002-01D

5 Remove exhaust flex pipe AR49.10-P-7170FF 6 Drain coolant AR20.00-P-1142FG 7.1 Remove poly-V-belt For vehicles with Code (I01) Air conditioning AR13.22-P-1202FG Plus or Code (I77) Manual AC 8.1 Remove the refrigerant compressor For vehicles with Code (I01) Air conditioning AR83.55-P-5300-04FG Plus or Code (I77) Manual AC *BA83.55-P-1002-01L

*BA83.55-P-1004-01L

9 Detach bottom coolant hose (1) at radiator Collect coolant which flows out in a suitable vessel. 10 Lower vehicle 11 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 12 Remove battery tray AR54.00-P-0002FF 13 Remove control unit for Electronic Diesel AR07.08-P-7006FF System (EDS) 14.1 Disconnect connector for pressure differential On vehicles with Code (K13) Diesel sensor (DPF) (26) at pressure differential particulate filter sensor (DPF) (B28/8) 15.1 Disconnect temperature sensor connector On vehicles with Code (K13) Diesel upstream diesel particulate filter (B19/9x1) particulate filter and temperature sensor connector upstream turbocharger (B19/11x1) 16.1 Unscrew bolt (25) On vehicles with Code (K13) Diesel particulate filter 17 Disconnect engine wiring harness AR01.00-P-2410-02FG *BA15.40-P-1001-01L

18.1 Detach shift cables from transmission. Only for transmission 717.473 AR26.60-P-6627-01FG 19 Loosen hose clamps (2) for coolant hoses (3) Collect coolant which flows out in a and detach coolant hoses (3) suitable vessel. Installation:

Do not interchange the coolant hoses (3). 20 Loosen hose clamp (4) and detach charge air hose (5) 21 Loosen hose clamp (6) and detach charge air hose (7) 22 Detach top coolant hose (8) at radiator Collect coolant which flows out in a suitable vessel. 23 Remove coolant hose (9) on expansion reservoir (10) 24 Unlock brake booster (11) vacuum line on the Actuate brake pedal a number of times in vacuum pump and detach order to remove any vacuum present. Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.10-p-2401fg, Remove, install engine with transmission ENGINE 639.9 in MODEL 454.0

Unscrew bolt (9) and unscrew nuts (7)¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1346 · Applies to: 453 · AR: AR33.30-P-0620FF, AR61.20-P-1105FF, AR25.20-P-0125FF

*454589006100

11 Unscrew bolt (9) and unscrew nuts (7) Install new self-locking bolt (9) and nuts (7). *BA26.00-P-1002-01D

*BA26.00-P-1003-01D

*454589040900

12 Remove front drive shafts Except engine 134.911 AR33.30-P-0620FF 13 Detach lower engine compartment paneling AR61.20-P-1105FF 14 Unhook retaining rubber (16). 15.1 Detach slave cylinder (13) and bracket (14) With transmission 717.470/471 AR25.20-P-0150-01FF from transmission (1) *BA25.20-P-1002-01D

15.2 Remove the clutch actuator With transmission 717.474 AR25.20-P-0125FF 16 Unscrew bolts (12) and remove flywheel cover (10) 17 Unscrew bolts of the transmission (1) on Do not unscrew bolts (11). engine at bottom. *BA26.10-P-1001-01D

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A

toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 18 Lower vehicle until the engine bridge can be lowered 19 Lower transmission (1) and engine with When lowering the transmission (1) engine bridge until the transmission (1) can be loosen the transmission bearing (8) from the taken out transmission (1) using a suitable screwdriver. *454589006100

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A

toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 20 Raise vehicle 21 Position removal fixture (17) under the The base jacks from the companies transmission (1) Mazzola and AS Hydraulic can be used according to choice. *450589026200

Base jack Co. Mazzola Base jack Fa. AS Hydraulic 22 Unscrew bolts (11), detach transmission (1) The base jacks from the companies from engine and put onto the removal fixture Mazzola and AS Hydraulic can be used (17). according to choice. Installation:

Grease transmission shaft slightly using suitable grease. *BA26.10-P-1001-01D

*450589026200

Base jack Co. Mazzola Base jack Fa. AS Hydraulic 23 Install in the reverse order 24.1 Teach in gear position, clutch motor with drag With transmission 717.474 point and shift actuator Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Clutch mechanism

Number Designation Model 454.0 BA25.20-P-1002-01D Torx bolt, clutch slave cylinder Nm 18 to transmission Complete manual transmission

Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar26.10-p-0020ff, Remove/install transmission TRANSMISSION 717.470 /471 /474 in MODEL 454.03

BE31.00-Z-9999CZ¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1494 · Applies to: 453 · AR: BE31.00-Z-9999CZ

Test and adjustment values: Smart: Frame, trailer operation 18.09.2019 MODEL all Test values for trailer hitch Model all (4xWD, CAR, Light transporter, BE31.11-P-1000-01A smart) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be31.00-z-9999cz, Test and adjustment values: Smart: Frame, trailer operation MODEL all

AR31.10-P-8000FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1496 · Applies to: 453 · AR: AR31.10-P-8000FF, AR49.10-P-4951FF

Remove/install trailer hitch 15.3.04 MODELS 454.0 with CODE (E50) Trailer hitch P31.10-2777-09 1 Trailer hitch 4 Filler neck 7 Reinforcement plate 5 Wheelhouse 2 Removal fixture

6 Bolts X58 Trailer hitch socket (13-pin) 3 Screw Remove/Install

1 Remove rear muffler AR49.10-P-4951FF 2 Detach 13-pin trailer hitch socket (X58) from the trailer hitch (1) 3 Unscrew bolt (3). Installation:

Replace bolt (3). *BA47.10-P-1003-01H

4 Support trailer hitch (1) with removal fixture The main lifters from the companies (2) Mazzola and AS Hydraulic can be used according to choice. *450589026200

WH58.30-Z-1011-07A Main lifter Co. Mazzola WH58.30-Z-1011-07A Main lifter Fa. AS Hydraulic 5 Loosen clips on the left and right wheelhouse (5) and push the left and right wheelhouse (5) to one side until the bolts (6) are accessible 6 Remove bolts (6) *BA31.11-P-1001-01D

7 Turn trailer hitch (1) and lead out under the Helper required vehicle using the removal fixture (2) Pay attention to filler neck (4). *450589026200

WH58.30-Z-1011-07A Main lifter Co. Mazzola WH58.30-Z-1011-07A Main lifter Fa. AS Hydraulic 8 Detach reinforcement plates (7) from the body *BA31.11-P-1001-01D

9 Install in the reverse order Trailer coupling mechanical system

Number Designation Model 454.0 BA31.11-P-1001-01D Bolt, trailer hitch to body Nm 58 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar31.10-p-8000ff, Remove/install trailer hitch MODELS 454.0 with CODE (E50) Trailer hitch

AP31.11-P-3121FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1500 · Applies to: 453 · AR: AP31.11-P-3121FF, AP31.11-P-3130FF

Lubricate and check operation of trailer hitch with detachable ball neck 8.6.06 MODEL 454.0 with CODE (E50) Trailer hitch 1 Ball neck P31.11-2105-01 Checking

1 Remove cover for ball neck mounting. 2 Remove ball neck (1) from vehicle If ball neck (1) and ball neck mounting are dirty - as a separate repair order: Clean trailer hitch with detachable ball neck. AP31.11-P-3130FF 3 Check diameter of coupling ball (arrows) *BE31.11-P-1001-01A The ball neck (1) must no longer be used if it measures less than the minimum size. 4 Check function of ball neck (1). See Operator's Manual If there are problems, the ball neck (1) must no longer be used. 5 Lubricate ball neck and ball neck mounting AP31.11-P-3121-04FF Automatic transmission fluids (ATF, Sheet Sheet 236.6 BB00.40-P-0236-06A

236.6) Automatic transmission fluids (ATF, Sheet Sheet 236.7 BB00.40-P-0236-07A

236.7) Automatic transmission fluids (ATF, Sheet Sheet 236.8 BB00.40-P-0236-08A

236.8) Multigrade engine oils (Sheet 228.1) Sheet 228.1 BB00.40-P-0228-01A

Multigrade engine oils (Sheet 228.3) Sheet 228.3 BB00.40-P-0228-03A

Grease (NLGI grade 1) Sheet 266.0 BB00.40-P-0266-00A

Multipurpose grease (NLGI Class 2) Sheet 267.0 BB00.40-P-0267-00A

6 Place ball neck (1) back in vehicle. 7 Attach cover for ball neck mounting Test values for trailer hitch Number Designation All models BE31.11-P-1001-01A Minimum diameter of ball head mm 49 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap31.11-p-3121ff, Lubricate and check operation of trailer hitch with detachable ball neck MODEL 454.0 with CODE (E50) Trailer hitch

AP31.11-P-3130FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1501 · Applies to: 453 · AR: AP31.11-P-3130FF

Trailer hitch with detachable ball neck - clean after testing 11.12.03 MODELS 454.0 with CODE (E50) Trailer hitch 1 Ball neck mounting 2 Ball neck 3 Release P31.11-2106-04 Cleaning

1 Clean ball neck mounting (1) To clean, use high pressure equipment/ steam cleaning equipment and dry with compressed-air. 2 Clean the ball neck (2) which has been Actuate the release (3) if necessary. removed The green marking on the hand wheel must align with the green marking on the ball neck (2). 3 Remove the key and press on the cover onto the lock 4 Clean ball neck (2) Only clean under flowing water, use a brush if necessary. Do not use high pressure equipment/steam cleaning equipment or solvents (e.g. pure benzine). 5 Dry ball neck (2) using a cloth Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap31.11-p-3130ff, Trailer hitch with detachable ball neck - clean after testing MODELS 454.0 with CODE (E50) Trailer hitch

PE31.19-P-2000ZC¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1502 · Applies to: 453 · AR: PE31.19-P-2000ZC, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Wiring diagram of trailer coupling 8.3.06 MODEL 454 as of 3.4.06 Trailer hitch accessories PE31.19-P-2000-99ZC Wiring diagram of trailer coupling PE31.19-P-2000-99ZC PE31.19-P-2000-60ZC trailer coupling PE31.19-P-2000-60ZC OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Location and assignment of line and plug GF00.19-P-1000ZA connectors GF00.19-P-2000ZA Location and assignment of ground points GF00.19-P-2000ZA GF00.19-P-3000ZA Location and assignment of Z connector GF00.19-P-3000ZA sleeves (line connectors in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe31.19-p-2000zc, Wiring diagram of trailer coupling MODEL 454 as of 3.4.06 Trailer hitch accessories

PE31.19-P-2000ZA¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1503 · Applies to: 453 · AR: PE31.19-P-2000ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Wiring diagram trailer coupling 16.12.03 MODEL 454 up to 2.4.06 PE31.19-P-2000-99ZA Wiring diagram trailer coupling PE31.19-P-2000-99ZA PE31.19-P-2000-60ZA Trailer coupling PE31.19-P-2000-60ZA OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Arrangement and assignment of the wiring GF00.19-P-1000ZA and plug connectors GF00.19-P-2000ZA Arrangement and assignment of ground GF00.19-P-2000ZA points GF00.19-P-3000ZA Arrangement and assignment of Z connector GF00.19-P-3000ZA sleeves (wiring connections in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe31.19-p-2000za, Wiring diagram trailer coupling MODEL 454 up to 2.4.06

PE31.19-P-2000ZB¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1504 · Applies to: 453 · AR: PE31.19-P-2000ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Wiring diagram trailer coupling 15.11.04 MODEL 454 up to 2.4.06 Anhängevorrichtung Zubehör PE31.19-P-2000-99ZB Wiring diagram trailer coupling PE31.19-P-2000-99ZB PE31.19-P-2000-60ZB trailer coupling PE31.19-P-2000-60ZB OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for electrical wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Location and assignment of line and plug GF00.19-P-1000ZA connectors GF00.19-P-2000ZA Location and assignment of ground points GF00.19-P-2000ZA GF00.19-P-3000ZA Location and assignment of Z connector GF00.19-P-3000ZA sleeves (line connectors in wiring harness) PE54.00-P-1100ZA Connecting wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe31.19-p-2000zb, Wiring diagram trailer coupling MODEL 454 up to 2.4.06 Anhängevorrichtung Zubehör'

AN32.20-P-0002FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1511 · Applies to: 453 · AR: AN32.20-P-0002FF, AR32.25-P-1018FF, AR32.25-P-0110FF, AR32.20-P-0230FF, AP82.10-P-8260FF

Install Brabus sport suspension 16.9.08 MODEL 454.0 with ENGINES 134.910, 135.930 /950 except CODE (E50) Trailer hitch Modification notes 15.9.08 Wheel alignment check omitted Remove/install

Risk of injury Use only approved tensioning devices; shield Danger! caused by pinching or AS00.00-Z-0001-01A

crushing off hazard area if necessary. when working on springs or spring bodies that are under tension Inspect special tools for damage and proper operation (visual inspection). Wear protective gloves. 1 Disassemble front suspension struts AR32.25-P-1018FF 2 Remove rear shock absorber AR32.25-P-0110FF 3 Remove rear springs AR32.20-P-0230FF 4 Install in the reverse order The parts from the Brabus parts kit must be used. 5 Check headlamp adjustment; correct if AP82.10-P-8260FF necessary 6 Enclose suspension modification certificate Suspension modification certificate * For Germany only OF32.20-P-1000-01FA Page 1 of 1 © Mercedes-Benz AG, 5/20/18, L/07/20, an32.20-p-0002ff, Install Brabus sport suspension MODEL 454.0 with ENGINES 134.910, 135.930 /950 except CODE (E50) Trailer hitch

AR32.20-P-0230FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1512 · Applies to: 453 · AR: AR32.20-P-0230FF

Remove/install rear spring 2.3.04 MODELS 454.0 1 Rear axle 2 Screw 3 Shock absorber 4 Rear spring 5 Removal fixture

P32.20-2103-11 Remove/Install

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A

toppling off of the lifting platform. hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. 1 Raise vehicle. 2 Position removal fixture (5) under the rear The main lifters from the companies axle (1) Mazzola and AS Hydraulic can be used according to choice. *450589026200

WH58.30-Z-1011-07A Main lifter Co. Mazzola WH58.30-Z-1011-07A Main lifter Fa. AS Hydraulic 3 Unscrew bolt (2) from the rear axle (1) *BA32.25-P-1001-03H

4 Lower basic lifter and press down rear axle (1) using a suitable tool *450589026200

WH58.30-Z-1011-07A Main lifter Co. Mazzola WH58.30-Z-1011-07A Main lifter Fa. AS Hydraulic 5 Remove rear spring (4) Check spring seats for damage and replace if necessary. 6 Install in the reverse order Rear axle shock absorber

Number Designation Model 454.0 BA32.25-P-1001-03H Bolt, shock absorber to rear axle Nm 95 450 589 02 62 00 Removal assembly Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.20-p-0230ff, Remove/install rear spring MODELS 454.0

AR32.20-P-0230SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1514 · Applies to: 453 · AR: AR32.20-P-0230SR

Remove/install rear spring 4.5.15 Model 453 P32.20-2324-09 1 Rear axle spring 5 Axle tube 8 Brake hoses 3 Screw 6 Rubber grommet 9 Rear axle center bearing 4 Shock absorber 7 Brake lines 10 Screw 1 Rear axle spring 5 Axle tube 12 Upper spring plate 13 Bottom spring retainer 13.1 End stop 13.2 Nipple P32.20-2325-06 Risk of death Danger ! caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.20-p-0230sr, Remove/install rear spring Model 453

AN32.20-P-0003FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1516 · Applies to: 453 · AR: AN32.20-P-0003FF, AR32.25-P-1018FF, AR32.20-P-0230FF, AP82.10-P-8260FF

Retrofit Brabus sport springs 16.9.08 MODEL 454.0 with ENGINES 134.910, 135.930 /950 except CODE (E50) Trailer hitch Modification notes 15.9.08 Wheel alignment check omitted Remove/install

Risk of injury Use only approved tensioning devices; shield Danger! caused by pinching or AS00.00-Z-0001-01A

crushing off hazard area if necessary. when working on springs or spring bodies that are under tension Inspect special tools for damage and proper operation (visual inspection). Wear protective gloves. 1 Disassemble front suspension struts AR32.25-P-1018FF 2 Remove rear springs AR32.20-P-0230FF 3 Install in the reverse order The parts from the parts kit for the Brabus sport springs must be used. 4 Check headlamp adjustment, adjust if AP82.10-P-8260FF necessary 5 Enclose suspension modification certificate Suspension modification certificate * For Germany only OF32.20-P-1000-01FA Page 1 of 1 © Mercedes-Benz AG, 5/20/18, L/07/20, an32.20-p-0003ff, Retrofit Brabus sport springs MODEL 454.0 with ENGINES 134.910, 135.930 /950 except CODE (E50) Trailer hitch

AR32.25-P-0121SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1519 · Applies to: 453 · AR: AR32.25-P-0121SR, AR32.25-P-1018SR, AR32.25-P-0110SR

Checking shock absorber 14.1.16 Model 453 Remove

1 Remove front shock absorbers When checking the front shock absorbers. AR32.25-P-1018SR 2 Remove rear shock absorbers When checking the rear shock absorbers. AR32.25-P-0110SR Check

3 Check damper for external oil leaks A thin film of oil on the shock absorber is

permissible. If there are problems: Replace shock absorber. * not for USA Service Information: Replacement of shock SI32.25-P-0002A

absorbers 4 Check piston rods for surface damage, If there are problems: bending and for unimpeded movement in the pilot bushing Replace shock absorber. * not for USA Service Information: Replacement of shock SI32.25-P-0002A

absorbers 5 Check elastomer bearings in housing eye When checking the rear shock absorbers. The elastomer bearings must be seated

securely in the housing eye and must not be cracked or damaged. If there are problems: Replace shock absorber. * not for USA Service Information: Replacement of shock SI32.25-P-0002A

absorbers Install

6 Install front shock absorbers After checking the front shock absorbers. AR32.25-P-1018SR 7 Install rear shock absorbers After checking the rear shock absorbers. AR32.25-P-0110SR Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.25-p-0121sr, Checking shock absorber Model 453

AR32.25-P-1018FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1520 · Applies to: 453 · AR: AR32.25-P-1018FF, AR32.25-P-1017FF

Disassemble/assemble suspension strut 26.3.08 MODEL 454.0 1 Suspension strut 2 Piston rod 3 Protective cap 4 Lower spring seat 5 Spring 6 Bellows 7 Upper spring seat 8 Pivot bearing 9 Spring cup 10 Nut 11 Assembly tool set A Socket wrench B Pin wrench P32.25-2115-06 Modification notes 18.3.08 General information on suspension strut noise complaint added Disassemble/assemble

Risk of injury Use only approved tensioning devices; shield Danger! caused by pinching or AS00.00-Z-0001-01A

crushing off hazard area if necessary. when working on springs or spring bodies that are under tension Inspect special tools for damage and proper operation (visual inspection). Wear protective gloves. If, because of a noise complaint, the

suspension strut (1) has to be disassembled, then the boots (6) must always be replaced in pairs. 1 Remove front spring strut (1) AR32.25-P-1017FF 2 Clamp assembly tool set (11) in vise Pay attention to correct seating of the assembly tool set (11) in the vise. *450589089900

3 Insert spring (5) in assembly tool set (11) The windings of the spring (5) must be gripped reliably in order to prevent the assembly tool set (11) from slipping off. Insert the lower and upper winding of the spring (5) in the assembly tool set (11) and preload lightly. Check again for the correct seating of the spring (5). *450589089900

4 Clamp spring (5) until the spring cup (9) is When clamping the spring (5), do not use exposed any impact wrench. Installation:

Pay attention to correct seat of spring (5). *450589089900

5 Unscrew nut (10) with socket wrench (A) Counterhold piston rod (2) with pin wrench (B). The socket wrench (A) and pin wrench (B) are parts of the set of socket wrench bits. Installation:

Replace nut (10). *BA32.25-P-1004-04I

*454589019900

6 Remove spring cup (9) with pivot bearing (8) and top spring seat (7) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.25-p-1018ff, Disassemble/assemble suspension strut MODEL 454.0

AR32.25-P-1018SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1522 · Applies to: 453 · AR: AR32.25-P-1018SR, AR32.25-P-1017SR

Disassemble/assemble suspension strut 7.12.15 Model 453 Modification notes 22.7.15 Special tool inserted P32.25-2348-08 1 Nut 4 Buffer 7 Spring seat 2 Spring cup 5 Bellows 8 Piston rod 3 Suspension strut mount 6 Spring 9 Shock absorber Risk of injury Danger ! caused by pinching or crushing Use only approved tensioning devices; AS00.00-Z-0001-01A

when working on springs or spring bodies that additionally screen off hazardous area if are under tension necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves. Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Remove

1 Remove suspension strut AR32.25-P-1017SR Disassemble/assemble

2 Remove spring (6) AR32.20-P-0200-05SR BA32.25-P-1002-04Q Nut, suspension strut mount to piston rod 453589006300 Clamping plates *203589013100 Tensioning device 3 Remove boot (5) from suspension strut mount (3) 4 Remove spring cup (2) from suspension strut mount (3) 5 Detach buffer (4) from piston rod (8) Check

6 Check spring cup (2) for wear and damage In the event of complaints Replace spring cup (2) 7 Check suspension strut mount (3) for wear In the event of complaints and damage Replace suspension strut bearing (3) 8 Check buffer (4), boot (5) and spring seat (7) If boot (5), buffer (4) or spring seat (7) are for wear, soiling and damage cracked, oiled up or deformed. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.25-p-1018sr, Disassemble/assemble suspension strut Model 453

Replace boot (5), buffer (4) or spring seat (7)¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1523 · Applies to: 453 · AR: AR32.25-P-0121SR, AR32.25-P-1017SR

9 Check spring (6) for damage In the event of complaints Replace spring (6) When replacing springs (6) note the color

codings on the spring coils. The color codings on the springs (6) of the left and right suspension strut may not vary. 10.1 Replace spring (6) on other side of vehicle When replacing a spring (6) and for a kilometer reading of > 60,000 km 10.2 Visually inspect spring (6) on other side of When replacing a spring (6) and for a vehicle for damage kilometer reading of < 60,000 km In the event of complaints Replace spring (6) 11 Check damper (9) for wear and damage AR32.25-P-0121SR 12 Assemble in the reverse order Install

13 Install suspension strut AR32.25-P-1017SR Suspension struts Number Designation Model 453 BA32.25-P-1002-04Q Nut, suspension strut mount to piston rod Nm 62 453 589 00 63 00 203 589 01 31 00 Clamping plates Tensioning device Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.25-p-1018sr, Disassemble/assemble suspension strut Model 453

AR32.25-P-0110FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1524 · Applies to: 453 · AR: AR32.25-P-0110FF, AR68.30-P-4800FF

Remove/install rear shock absorber 13.8.03 MODELS 454.0 P32.25-2101-07 illustrated on left side of vehicle 2 Screw 5 Nut 3 Panel 6 Upper rubber mount 1 Shock absorber 4 Piston rod 7 Washer Remove/Install

Notes on self-locking nuts and bolts AH00.00-N-0001-01A 1 Remove paneling (3) in the side of the AR68.30-P-4800FF luggage compartment 2 Unscrew nut (5) of damper (1) In order to prevent the springs jumping out or the brake hoses tearing, do not remove both dampers (1) simultaneously. Counterhold piston rod (4). *BA32.25-P-1002-03H

3 Remove washer (7) and upper rubber mount (6) 4 Unscrew bolt (2) of damper (1) In order to prevent the springs jumping out or the brake hoses tearing, do not remove both dampers (1) simultaneously. *BA32.25-P-1001-03H

5 Remove damper (1) 6 Install in the reverse order Rear axle shock absorber

Number Designation Type 454.0 BA32.25-P-1001-03H Bolt, shock absorber to rear axle Nm 95 BA32.25-P-1002-03H Nut, damper to body Nm 22 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.25-p-0110ff, Remove/install rear shock absorber MODELS 454.0

AR32.25-P-0110SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1525 · Applies to: 453 · AR: AR32.25-P-0110SR, AR68.30-P-4800SRC, AR68.30-P-4800SR, AR68.30-P-4800SRA

Remove/install rear shock absorber 16.12.15 Model 453 P32.25-2344-09 Shown on model 453.3 1 Shock absorber 3 Nut 6 Screw 2 Piston rod 5 Elastomer bearing 7 Elastomer bearing Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Remove/install

1 Remove left or right lower cover in the trunk Model 453.4 AR68.30-P-4800SRC Model 453.0 AR68.30-P-4800SR Model 453.3 AR68.30-P-4800SRA 2 Unscrew nut (3)

Counterhold piston rod (2) and do not use an impact wrench. Otherwise, the shock absorber (1) can be damaged. Installation: In order to tighten the nuts

(3), the vehicle must have its suspension compressed. *BA32.25-P-1002-03Q Nut, shock absorber to body 3 Remove elastomer bearing (5) Installation: Check condition of elastomer

bearing (5). In the event of complaints Replace elastomer bearing (5) Risk of death Danger ! caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. 4 Raise vehicle with vehicle lift Installation: When lowering the vehicle

lift, ensure that the piston rod (2) retracts into the hole of the body. 5 Unscrew screw/bolt (6) and remove it *BA32.25-P-1001-03Q Bolt, shock absorber to rear axle 6 Press piston rod (2) into the shock absorber (1) up to end stop and remove shock absorber (1) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.25-p-0110sr, Remove/install rear shock absorber Model 453

Remove elastomer bearing (7) from piston¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1526 · Applies to: 453 · AR: AR32.25-P-0121SR

7 Remove elastomer bearing (7) from piston Installation: Check condition of elastomer

rod (2) bearing (7). In the event of complaints Replace elastomer bearing (7) Check

8 Check shock absorber (1) AR32.25-P-0121SR 9 Install in the reverse order Rear axle shock absorber Number Designation Model 453 BA32.25-P-1001-03Q Bolt, shock absorber to rear axle Nm 105 Rear axle shock absorber Number Designation Model 453 BA32.25-P-1002-03Q Nut, shock absorber to body Nm 21 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.25-p-0110sr, Remove/install rear shock absorber Model 453

AR32.25-P-1017FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1527 · Applies to: 453 · AR: AR32.25-P-1017FF, AR40.10-P-1100FF, AR88.00-P-2792FF, AP82.10-P-8260FF

Remove/install the suspension strut 20.9.10 MODEL 454.0 P32.25-2114-07 1 Electrical line 4 Suspension strut 6 Bolts 2 Brake hose bracket 5 Nuts 7 Nuts 3 Link rod (except model 454.034) Remove/install

Replace self-locking nuts and bolts.

1 Remove left front wheel or right front wheel AR40.10-P-1100FF 2 Remove electrical line (1) from the bracket on the suspension strut (4) 3 Detach brake hose bracket (2) from *BA42.10-P-1002-04G

suspension strut (4) 4 Detach connecting rod (3) from spring strut (4)Except model 454.034 *BA32.25-P-1003-04I

5 Unscrew nuts (5) and bolts (6) *BA32.25-P-1002-04I

6 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 7 Unscrew nuts (7) *BA32.25-P-1001-04I

8 Carefully remove suspension strut (4) Push transverse control arm on front axle downwards down only as far as required, as otherwise the rubber bushings in the transverse control arm may be damaged. Do not damage the front CBS, as otherwise it will have to be repaired or replaced. 9 Install in the reverse order 10 Check headlamp setting; correct it if AP82.10-P-8260FF necessary Suspension struts

Number Designation Model Model 454.0 454.034 except model 454.034 BA32.25-P-1001-04I Nut, strut to body Nm 30 30 BA32.25-P-1002-04I Nut, spring strut to steering knuckle Nm 90 96 BA32.25-P-1003-04I Nut, link rod to suspension strut Nm 28 - Brake lines, brake hoses

Number Designation Model Model 454.0 with 454.0 code 30Y without code 30Y Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.25-p-1017ff, Remove/install the suspension strut MODEL 454.0

AR32.25-P-1017SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1529 · Applies to: 453 · AR: AR32.25-P-1017SR, AR82.30-P-6800SR

Remove/install the suspension strut 28.08.2017 Model 453 Modification notes 28.08.2017 Nut, connecting linkage to suspension strut BA32.20-P-1001-02S 2 Bolts P32.25-2345-06 1 Suspension strut 3 Bracket 4 Electrical line 5 Brake hose 6 Connecting linkage 7 Nut 8 Nuts 9 Bolts 10 Steering knuckle P32.25-2346-06 Topical note Notes on self-locking nuts and bolts AH00.00-N-0001-01A Notes on repair work on suspension AH00.00-P-0100-01A components Remove/install

1 Remove wiper motor When removing the left suspension strut (1). AR82.30-P-6800SR Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar32.25-p-1017sr, Remove/install the suspension strut Model 453

SM32.25-P-0016A¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1531 · Applies to: 453 · AR: AR32.25-P-1017SR, AR32.25-P-1018SR, AR40.20-P-0200SR

Replace front axle shock absorber (code: 1505P32B02) 28.08.2017 Model 453 Modification notes 28.08.2017 Nut, connecting linkage to suspension strut BA32.20-P-1001-02S Operation no. of the operation texts or standard texts and flat rates Category Op. no. Operation text Time Acc. no. Code C 02-8997 Replace 2 front shock absorbers Check

1 Check whether vehicle is affected by measure Model 453 as of 000034 up to 008727 SM32.25-P-0016-01AAA Remove

2 Remove both front suspension struts AR32.25-P-1017SR

Disassemble

3 Disassemble both front suspension struts AR32.25-P-1018SR

Only use approved spring compressor.

453589006300 Clamping plates 203589013100 Tensioning device Install

4 Replace both front shock absorbers 5 Replace both stop buffers Assemble

6 Assemble both front suspension struts AR32.25-P-1018SR

Only use approved spring compressor.

453589006300 Clamping plates 203589013100 Tensioning device Install

7 Install both front suspension struts AR32.25-P-1017SR

BA32.25-P-1002-04Q Nut, suspension strut mount to piston rod BA32.20-P-1001-02S Nut, connecting linkage to suspension strut BA32.25-P-1003-04Q Bolt of suspension strut to steering knuckle BA32.25-P-1001-04Q Bolt, suspension strut to body 8 Perform wheel alignment check and adjust AR40.20-P-0200SR

Front axle stabilizer bar Number Designation Model 453 BA32.20-P-1001-02S Nut, connecting linkage to suspension strut Nm 50 Suspension struts Number Designation Model 453 BA32.25-P-1001-04Q Bolt, suspension strut to body Nm 21 Suspension struts Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, sm32.25-p-0016a, Replace front axle shock absorber (code: 1505P32B02) Model 453

AR32.35-P-2050FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1535 · Applies to: 453 · AR: AR32.35-P-2050FF, AR46.20-P-0600FF

Remove/install front anti-roll bar 9.6.06 MODEL 454.0 Shown on engine 639.9 1 Stabilizer 2 Link rod 3 Bolts 4 Clip 5 Rubber bushing 6 Front axle carrier 7 Rack-and-pinion steering P32.25-2180-06 Modification notes 10.3.06 Bolt, retaining clamp to torsion bar Model 454.0 *BA32.20-P-1001-01K Remove/install

1 Disassemble rack-and-pinion steering (7) on AR46.20-P-0600FF Do not take off rack-and-pinion steering front axle carrier (6) until the bolts (3) of the (7). clamps (4) are accessible 2 Remove link rods (2) on stabilizer bar (1) Engine 122.9 AR32.35-P-2050-05FB *BA32.20-P-1002-01K

Engine 134.9, 135.9, 639.9 AR32.35-P-2050-05FF *BA32.20-P-1002-01K

3 Remove bolts (3) *BA32.20-P-1001-01K

4 Take off clamps (4) and rubber bushing (5) Installation:

Note the installation position of the rubber bushings (5). 5 Take off stabilizer bar (1) from front axle carrier (6) 6 Install in the reverse order Front axle stabilizer bar

Number Designation Model 454.0 BA32.20-P-1001-01K Bolt, retaining clamp to torsion bar Nm 35 BA32.20-P-1002-01K Nut, link rod to stabilizer bar Nm 28 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.35-p-2050ff, Remove/install front anti-roll bar MODEL 454.0

AR32.35-P-2050SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1536 · Applies to: 453 · AR: AR32.35-P-2050SR, AR88.20-P-2000SR, AR88.20-P-2000SRA, AR62.10-P-1020SR

Remove/install front stabilizer bar 21.12.15 Model 453 1 Stabilizer 2 Nuts 3 Connecting linkage 4 Bolt 5 Clip 6 Elastomer bearing P32.35-2052-06 Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Remove/install

1 Remove front bumper Model 453.0 AR88.20-P-2000SR Model 453.3/4 AR88.20-P-2000SRA 2 Remove CMS front AR62.10-P-1020SR 3 Unclip and remove air duct segment in front of cooler 4 Counterhold threaded pin of connecting rod Installation: Replace self-locking nuts (2).

(3) and unscrew nuts (2) BA32.20-P-1002-02S Nut, connecting linkage to stabilizer bar 450589001700 Range of tools for stabilizer bar assembly *126589001000 Screwdriver bit 5 Unhook connecting rod (3) from stabilizer bar (1) 6 Remove bolts (4) of clamps (5) Installation: The opening of the elastomer

bearing (6) must point in the direction of travel. *BA32.20-P-1003-02S Bolt, retaining clamp for stabilizer bar to front axle 7 Remove stabilizer bar (1) towards front in

direction of arrow Lift stabilizer bar (1) carefully over front axle in direction of arrow and remove. Otherwise, the condenser may be damaged. Check

8 Check elastomer bearings (6) for damage In event of damaged elastomer bearings (6) Replace stabilizer bar (1) 9 Install in the reverse order Front axle stabilizer bar Number Designation Model 453 BA32.20-P-1002-02S Nut, connecting linkage to stabilizer bar Nm 44 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.35-p-2050sr, Remove/install front stabilizer bar Model 453

AR32.35-P-3328SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1538 · Applies to: 453 · AR: AR32.35-P-3328SR, AR00.60-P-0100SR

Remove/install front stabilizer bar link rod 28.08.2017 Model 453 Modification notes 07.07.2016 Document completely revised 28.08.2017 Nut, connecting linkage to suspension strut BA32.20-P-1001-02S 1 Stabilizer linkage 2 Nut 3 Nut P32.35-2048-04 Topical note Notes on self-locking nuts and bolts AH00.00-N-0001-01A Remove/install

Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. 1 Raise vehicle with vehicle lift AR00.60-P-0100SR 2 Turn steering at wheel To improve accessibility.

3 Counterhold threaded pin of left or right Installation: Replace self-locking nuts

stabilizer bar linkage (1) and unscrew nuts (2,3). (2,3) at left or right stabilizer bar linkage (1) BA32.20-P-1001-02S Nut, connecting linkage to suspension strut BA32.20-P-1002-02S Nut, connecting linkage to stabilizer bar 126589001000 Screwdriver bit 450589001700 Range of tools for stabilizer bar assembly 4 Remove stabilizer bar linkage (1) 5 Install in the reverse order Front axle stabilizer bar Number Designation Model 453 BA32.20-P-1001-02S Nut, connecting linkage to suspension strut Nm 50 Front axle stabilizer bar Number Designation Model 453 BA32.20-P-1002-02S Nut, connecting linkage to stabilizer bar Nm 44 126 589 00 10 00 450 589 00 17 00 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.35-p-3328sr, Remove/install front stabilizer bar link rod Model 453

AR32.35-P-1221SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1540 · Applies to: 453 · AR: AR32.35-P-1221SR, AR00.60-P-0100SR

Remove/install front stabilizer bar torsion bar linkage 28.08.2017 Model 453 Modification notes 28.08.2017 Nut, connecting linkage to suspension strut BA32.20-P-1001-02S 1 Torsion bar linkage 2 Nut 3 Nut P32.35-2048-04 Topical note Notes on self-locking nuts and bolts AH00.00-N-0001-01A Remove/install

Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. 1 Raise vehicle with vehicle lift
AR00.60-P-0100SR 2 Turn steering at wheel To improve accessibility.

3 Counterhold threaded pin of torsion bar Installation: Replace the self-locking nuts

linkage (1) on left and right and unscrew nuts (2, 3). (2, 3) on left and right torsion bar linkage (1) BA32.20-P-1001-02S Nut, connecting linkage to suspension strut BA32.20-P-1002-02S Nut, connecting linkage to stabilizer bar 126589001000 Screwdriver bit 450589001700 Range of tools for stabilizer bar assembly 4 Remove torsion bar linkage (1) 5 Install in the reverse order Front axle stabilizer bar Number Designation Model 453 BA32.20-P-1001-02S Nut, connecting linkage to suspension strut Nm 50 Front axle stabilizer bar Number Designation Model 453 BA32.20-P-1002-02S Nut, connecting linkage to stabilizer bar Nm 44 126 589 00 10 00 450 589 00 17 00 Screwdriver bit Range of tools for stabilizer bar assembly Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar32.35-p-1221sr, Remove/install front stabilizer bar torsion bar linkage Model 453

AR33.10-P-0003SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1552 · Applies to: 453 · AR: AR33.10-P-0003SR

Lower and position front axle 16.12.15 Model 453 P33.10-2431-07 Shown on right side of vehicle 2 Bolts 7 Electrical connector 12 Brake hose 3 Suspension strut tower 8 Fender liner 13 Brake line 4 Suspension strut 9 Electrical line 14 Bracket 5 Stabilizer 10 Bracket 6 Nut 11 Retaining screw 19 Nut 20 Ball joint 21 Steering gear 22 Electrical connector P33.10-2432-04 P33.10-2433-07 1 Front axle 24 Bolts 23 Screw 30 Rubber guide Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.10-p-0003sr, Lower and position front axle Model 453

AR33.10-P-0100SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1555 · Applies to: 453 · AR: AR33.10-P-0100SR

Remove/install front axle 16.12.15 Model 453 P33.10-2431-07 Shown on right side of vehicle 2 Bolts 7 Electrical connector 12 Brake hose 3 Suspension strut tower 8 Fender liner 13 Brake line 4 Suspension strut 9 Electrical line 14 Bracket 5 Stabilizer 10 Bracket 6 Nut 11 Retaining screw 19 Nut 20 Ball joint 21 Steering gear 22 Electrical connector P33.10-2432-04 P33.10-2433-07 1 Front axle 24 Bolts 23 Screw 30 Rubber guide Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.10-p-0100sr, Remove/install front axle Model 453

AR33.10-P-0001FB¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1559 · Applies to: 453 · AR: AR33.10-P-0001FB

Remove/install front axle carrier 9.6.06 MODEL 454.0 with ENGINE 122.9, 639.9 Illustrated on model 454.034 1 Bolt 2 Jacket tube 3 Boot 4 Rack-and-pinion steering 5 Floor Covering 6 Electrical connector 7 Electrical connector 8 Electrical wiring P33.10-2230-06 P33.10-2229-09 Shown on engine 122.9 3 Boot 10 Rubber retainers 14 Belt

4 Rack-and-pinion steering 11 Bolts 15 Bolt 8 Electrical wiring 12 Bracket 16 Stabilizer 9 Front axle carrier 13 Removal fixture 17 Lower transmission bearing

Remove/install

1 Turn Steering to middle position and remove Determine number of steering wheel turns ignition key between left and right full lock. Turn steering wheel back from full lock through one half of determined value. 2 Fold up floor covering (5) in area of jacket Fold up floor covering (5) carefully tube (2) until the bolt (1) is accessible otherwise floor covering (5) could be damaged. 3 Remove bolt (1) and detach jacket tube (2) Replace self-locking bolt (1). from rack-and-pinion steering (4) Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.10-p-0001fb, Remove/install front axle carrier MODEL 454.0 with ENGINE 122.9, 639.9

*BA46.10-P-1001-05A¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1560 · Applies to: 453 · AR: AR33.20-P-1452FB, AR40.20-P-0200FF

4 Unclip boot (3) 5 Fold up floor covering (5) on right under Fold up floor covering (5) carefully instrument panel until electrical connectors (6, otherwise floor covering (5) could be 7) are accessible damaged. 6 Disconnect electrical connectors (6, 7) and Installation:

Check for correct seating of route electrical lines (8) through opening into grommet for electrical lines (8) in the splash engine compartment wall. 7 Remove transverse control arm AR33.20-P-1452FB Do not pry off the transverse control arm from the steering knuckle. 8 Detach tie rod ends from steering knuckles AR46.40-P-0200-02FF *BA46.40-P-1001-01I

*450589013300

9.1 Remove link rods on stabilizer bar (16) Only for engine 639.9 AR32.35-P-2050-05FF *BA32.20-P-1002-01K

10 Detach rubber retainers (10) from front axle carrier (9) 11 Remove bolts (11) and take off bracket (12) *BA26.00-P-1005-01D

12 Position removal fixture (13) under front axle The base jacks from the companies carrier (9) Mazzola and AS Hydraulic can be used according to choice. *450589026200

WH58.30-Z-1011-07A Base jack Co. Mazzola WH58.30-Z-1011-07A Base jack Fa. AS Hydraulic 13 Secure front axle carrier (9) using belt (14) of *450589026200

removal fixture (13) 14 Remove bolts (15) *BA33.10-P-1001-01F

15 Lower removal fixture (13) with front axle Observe electrical lines (8). carrier (9) When replacing the front axle carrier (9), the rack-and-pinion steering (4), the lower transmission bearing (17) and the stabilizer bar (16) have to be modified. Installation:

Ensure that the boot (3) in the firewall is seated correctly. *450589026200

WH58.30-Z-1011-07A Base jack Co. Mazzola WH58.30-Z-1011-07A Base jack Fa. AS Hydraulic 16 Install in the reverse order 17 Perform chassis alignment AR40.20-P-0200FF Complete manual transmission

Number Designation Transmis- Transmis- sion sion 717 717.478 except 717.478 BA26.00-P-1005-01D Bolt, lower transmission bearing to Nm 58 58 transmission Front axle stabilizer bar

Number Designation Model 454.0 BA32.20-P-1002-01K Nut, link rod to stabilizer bar Nm 28 Front axle carrier

Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.10-p-0001fb, Remove/install front axle carrier MODEL 454.0 with ENGINE 122.9, 639.9

AR33.10-P-0001FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1562 · Applies to: 453 · AR: AR33.10-P-0001FF, AR40.10-P-1100FF

Remove/install front axle carrier 9.6.06 MODEL 454.0 with ENGINE 134.9, 135.9 1 Jacket tube 2 Bolt 3 Floor Covering 4 Electrical connectors 5 Electrical wiring 20 Boot P33.10-2192-06 P33.10-2191-07 6 Link rod 9 Rubber retainers 12 Bolts 7 Stabilizer 10 Front axle carrier 13 Belt

8 Bolts 11 Removal fixture 14 Bracket

Remove/install

1 Turn steering to middle position and remove Determine number of steering wheel turns ignition key between left and right full lock. Turn steering wheel back from full lock through one half of determined value. 2 Fold up floor covering (3) in area of jacket Fold up floor covering (3) carefully tube (1) until the bolt (2) is accessible otherwise floor covering (3) could be damaged. 3 Remove bolt (2) and detach jacket tube (1) Replace self-locking bolt (2). from rack-and-pinion steering *BA46.10-P-1001-05A

4 Unclip boot (20) 5 Fold up floor covering (3) on right under Fold up floor covering (3) carefully instrument panel until electrical connectors (4) otherwise floor covering (3) could be are accessible damaged. 6 Disconnect electrical connectors (4) and route Installation:

Check for correct seating of electrical lines (5) through opening into engine grommet for electrical lines (5) in the splash compartment wall. 7 Remove front wheels AR40.10-P-1100FF 8 Detach tie rod ends from steering knuckles AR46.40-P-0200-02FF *BA46.40-P-1001-01I

*450589013300

9 Detach flange ball joints from steering AR33.20-P-0446-01FF knuckles Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.10-p-0001ff, Remove/install front axle carrier MODEL 454.0 with ENGINE 134.9, 135.9

AR33.20-P-0446SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1565 · Applies to: 453 · AR: AR33.20-P-0446SR, AR33.20-P-1452SR

Remove/install flange ball joint 4.5.15 Model 453 1 Flange ball joint 1.1 Pin 1.2 Collar 2 Transverse control arm P46.40-2112-06 1 Flange ball joint 1.1 Pin 2 Transverse control arm 3 Sleeve 4 Ram 5 Sleeve P46.40-2113-06 Remove

1 Remove transverse control arm (2) AR33.20-P-1452SR Check

2 Check that a retaining ring is present in If no retaining ring is attached: flange ball joint (1) (retaining ring may be in groove (arrow A) of flange ball joint (1)) Replace flange ball joint (1) as described in following operation steps. If a retaining ring is attached: Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.20-p-0446sr, Remove/install flange ball joint Model 453

Replace transverse control arm (2) and flange¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1566 · Applies to: 453 · AR: AR33.20-P-1452SR

ball joint (1). 3 Position suitable sleeve (3) in press The inside diameter of the sleeve (3) must

not be less than the outside diameter of the collar (1.2). 4 Place transverse control arm (2) on sleeve (3) 5 Pre-tension press and align transverse The pin (1.1) must be flush with the stamp

control arm (2) together with flange ball joint (4); the collar (1.2) must be inside the sleeve (1) with sleeve (3) and stamp (4) (3). 6 Press out flange ball joint (1) Install

7 Place turned-over transverse control arm (2) on sleeve (3) 8 Position flange ball joint (1) on transverse If aligned correctly, the flattened side

control arm (2) and align (arrow B) of the flange ball joint (1) should be on the side not facing the transverse control arm (2). 9 Place suitable sleeve (5) on collar (1.2) of

flange ball joint (1) The press pressure must act only on the collar (1.2), i.e. the inside diameter of the sleeve (5) must not be less than the inside diameter of the collar (1.2). The flange ball joint (1) can otherwise be damaged. 10 Press in flange ball joint (1) fully 11 Place plastic cover on flange ball joint (1) The plastic cover is included in the

package contents of the flange ball joint (1). 12 Slide retaining ring from above over plastic cover and insert into groove (arrow A) of flange ball joint (1) 13 Remove plastic cover from flange ball joint (1) 14 Install transverse control arm (2) AR33.20-P-1452SR Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.20-p-0446sr, Remove/install flange ball joint Model 453

AR33.20-P-1452SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1568 · Applies to: 453 · AR: AR33.20-P-1452SR, AR40.10-P-1100SR, AR40.20-P-0200SR

Remove/install front axle transverse control arm 28.08.2019 Model 453 Modification notes 28.08.2019 Wheel alignment measurement added. Operation step 8 P33.20-2285-09 1 Transverse control arm 4 Nut 7 Front axle 2 Flange ball joint 5 Steering knuckle 8 Bolts 3 Screw 6 Nuts Topical note Notes on self-locking nuts and bolts AH00.00-N-0001-01A Notes on repair work on suspension AH00.00-P-0100-01A components Remove/install

1 Remove left or right front wheel. AR40.10-P-1100SR 2 Counterhold nut (4) with a suitable tool and BA33.25-P-1001-01F Bolt, flange ball joint to steering knuckle remove screw (3).
3 Spread steering knuckle (5) with a suitable tool and unhook flange ball joint (2). 4 Counterhold nuts (6) with a suitable tool and BA33.15-P-1001-01F Screw/bolt, transverse control arm to front remove screws (8). axle carrier 5 Remove transverse control arm (1).
Check

6 Check boot at flange ball joint (2) for good In the event of a problem, condition. replace transverse control arm (1). 7 Install in the reverse order. 8 Perform chassis alignment. AR40.20-P-0200SR Trailing arms, transverse control arms Number Designation Model 453 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.20-p-1452sr, Remove/install front axle transverse control arm Model 453

AR33.20-P-0302SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1570 · Applies to: 453 · AR: AR33.20-P-0302SR, AR33.25-P-0400SR

Remove/install wheel bearing 15.07.2016 Model 453 1 Steering knuckle 2 Cap 3 Counterholder 4 Wheel hub 5 Nut 6 Wheel bearings 6.1 Pulse ring 7 Retaining ring P33.20-2304-06 Remove/install

1 Remove steering knuckle (1) AR33.25-P-0400SR 2 Clamp steering knuckle (1) in a vise 3 Remove cap (2) Installation: Install a new cap (2).

4 Attach a suitable counterholder (3) to wheel hub (4) 5 Counterhold wheel hub (4) and unscrew nut Installation: Replace and caulk nut (5)

(5) (arrows A). *BA33.20-P-1001-01V Nut, wheel hub to wheel bearing 6 Detach counterholder (3) 7 Take steering knuckle (1) out of vise 8 Press out wheel hub (4)

Do not support the steering knuckle (1) on the brake caliper support mounts. They can be damaged otherwise. Installation:

The inner races of the wheel bearing (6) must be supported using a sleeve. Otherwise the wheel bearing (6) will be damaged. Installation: Install a new wheel hub (4).

Commercially available devices/tools

Workshop press 9 Commercially available devices/tools Remove retaining ring (7)

Circlip pliers Installation: Replace locking ring (7).

10 Installation: Press out wheel bearing (6)

Install components in correct positions. The pulse ring (6.1) must be on the inside. An incorrectly pressed-in wheel bearing (6) cannot generate rpm signals and will be damaged when pressed out. Installation:

The inner races of the wheel bearing (6) must not be subjected to loads. Otherwise the wheel bearing (6) can be damaged. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.20-p-0302sr, Remove/install wheel bearing Model 453

AR33.20-P-1452FB¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1572 · Applies to: 453 · AR: AR33.20-P-1452FB, AR40.10-P-1100FF, AP18.00-P-0101FB, AR32.35-P-3328FB

Removing and installing front axle wishbone 6.12.04 MODEL 454.0 with ENGINE 122.950, 639.939 Illustrated on model 454.034 1 Front axle shaft 2 Nut 3 Transverse control arm 4 Bolt 5 Bolt 6 Steering knuckle 7 Flange joint P33.20-2159-06 Remove

1.1 Detach left or right wheel cover on the front On vehicles with steel rims. axle 1.2 Detach left or right wheel on the front axle On vehicles with aluminum rims. AR40.10-P-1100FF 2 Clean thread of the front axle shaft (1) with a The thread of the front axle shaft (1) must wire brush and coat a suitable lubricant be free from corrosion and dirt, otherwise there will be risk of damage to the front axle shaft (1) when unscrewing the nut (2). 3.1 Remove cover of the nut (2) in the aluminum Only on vehicles with aluminum rims. rim, put on left or right wheel and screw on until it abuts using two lug nuts Do not tighten lug nuts. 4.1 Lower vehicle Only on vehicles with aluminum rims. 5 Slacken nut (2) In order to avoid damage to the thread of the front axle shaft (1) the nut (2) should not be loosened with an impact wrench under any circumstances. The nut (2) may only be loosened using a suitable locking handle. 6 Detach left or right wheel on the front axle AR40.10-P-1100FF 7 Unscrew nut (2) and remove with washer In order to avoid damage to the thread of the front axle shaft (1) the nut (2) should not be loosened with an impact wrench under any circumstances. The nut (2) may only be loosened using a suitable locking handle. If the thread is damaged nevertheless, it should be recut and the front axle shaft (1) replaced if necessary. 8.1 Unscrew oil filter Only on model 454.034 and when removing the right transverse control arm (3). See: Engine oil and filter change AP18.00-P-0101FB

9.1 Remove front stabilizer bar link rod Only on model 454.034 AR32.35-P-3328FB 10 Unscrew bolts (4, 5) on transverse control arm (3) 11 Pull steering knuckle (6) back and pull front axle shaft (1) out of steering knuckle (6) 12 Press flange joint (7) off steering knuckle (6) AR33.20-P-0446-01FF *454589003300

13 Remove transverse control arm (3) Install

14 Install transverse control arm (3) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.20-p-1452fb, Removing and installing front axle wishbone MODEL 454.0 with ENGINE 122.950, 639.939

Attach flange joint (7) to steering knuckle (6)¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1573 · Applies to: 453 · AR: AR32.35-P-3328FB, AP18.00-P-0101FB, AR40.10-P-1100FF

15 Attach flange joint (7) to steering knuckle (6) AR33.20-P-0446-01FF *BA33.15-P-1002-01D

16 Pull steering knuckle (6) outwards and push front axle shaft (1) into steering knuckle (6) 17 Tighten bolt (4, 5) on transverse control arm *BA33.15-P-1001-01D

(3) 18.1 Install front stabilizer bar link rod Only on model 454.034 AR32.35-P-3328FB 19.1 Mount oil filter Only on model 454.034 and when removing the right transverse control arm (3). Replace oil filter Refer to: Engine oil and filter change AP18.00-P-0101FB

20 Screw on nut (2) Install new self-locking nut (2). In order to avoid damage to the thread of the front axle shaft (1) the nut (2) should not be screwed on with an impact wrench under any circumstances. The nut (2) may only be screwed on with a suitable locking handle or torque wrench. 21 Mount the left or right wheel on the front axle AR40.10-P-1100FF Do not mount wheel cover on vehicles with steel rims or cover of nut (2) on vehicles with aluminum rims. 22 Tighten nut (2) In order to avoid damage to the thread of the front axle shaft (1) the nut (2) should not be screwed on with an impact wrench under any circumstances. The nut (2) may only be tightened with a torque wrench. *BA33.30-P-1001-07B

23.1 Mount left or right wheel cover on front axle Only on vehicles with steel wheels. 23.2 Mount left or right cover of nut (2) on Only on vehicles with aluminum rims. aluminum rim Trailing arms, wishbones

Number Designation Model Model 454.0 with 454.0 with engine engine 122.950 639.939 BA33.15-P-1001-01D Bolt, wishbone to front axle carrier Nm 158 158 BA33.15-P-1002-01D Nut, flange joint to steering knuckle Nm 60 60 Input shaft

Number Designation Engine Engine 122.950 639.939 BA33.30-P-1001-07B Nut, drive shaft to wheel bearing Nm 236 235 454 589 00 33 00 Puller Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.20-p-1452fb, Removing and installing front axle wishbone MODEL 454.0 with ENGINE 122.950, 639.939

SM33.20-P-0015A¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1574 · Applies to: 453 · AR: AR33.20-P-0302SR

Replace front axle wheel hub (code 1605P42B43) 07.10.2016 Model 453.3 Operation no. of the operation texts or standard texts and flat rates Category Op. no. Operation text Time Acc. no. Code P 02-9515 Replace front axle components Check

1 Check whether vehicle is affected by Model 453.3 as of 083690 up to 099026 SM33.20-P-0015-01AAA measure Install

2 Replace front axle wheel bearings AR33.20-P-0302SR

Replace wheel hubs, brake disks and

brake linings. The part number for the brake disk parts kit

and brake lining parts kit must be determined according to the VIN via the EPC. Parts ordering note Part no. Designation Quantity A 453 334 00 00 Left and right wheel hub 2 A 453 334 02 00 Parts kit for left and right wheel bearing 2 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, sm33.20-p-0015a, Replace front axle wheel hub (code 1605P42B43) Model 453.3

AR33.25-P-0400FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1575 · Applies to: 453 · AR: AR33.25-P-0400FF, AR40.10-P-1100FF

Remove/install steering knuckle 20.9.10 MODEL 454.0 with ENGINE 122.9, 134.9, 135.9, 639.9 P33.25-2017-09 1 Nut 5 Caliper support L6/1 Left front rpm sensor 2 Screw 6 Brake disk L6/2 Right front rpm sensor 3 Steering knuckle 7 Nuts 4 Bolts 8 Bolts Removing

1.1 Detach left or right wheel cover on the front On vehicles with steel rims. axle 1.2 Detach left or right wheel on the front axle On vehicles with aluminum rims. AR40.10-P-1100FF 2 Clean the thread of the front axle shaft with a The thread of the front axle shaft must be wire brush and coat with a suitable lubricant free from corrosion and dirt, otherwise the front axle shaft may be damaged when unscrewing the nut (1). 3 Remove cover of the nut (1) in the aluminum On vehicles with aluminum rims. rim, put on left or right wheel and screw on until it abuts using two wheel nuts 4 Lower vehicle On vehicles with aluminum rims. 5 Slacken nut (1) In order to avoid damage to the thread of the front axle shaft the nut (1) should not be released using an impact wrench. The nut (1) must be loosened using a suitable locking handle. 6 Detach left or right wheel on the front axle AR40.10-P-1100FF 7 Unscrew nut (1) In order to avoid damage to the thread of the front axle shaft the nut (1) should not be unscrewed using an impact wrench. The nut (1) must be unscrewed using a suitable locking handle. In the event of the thread being damaged nevertheless it should be recut and the front axle shaft replaced if necessary. 8 Unscrew screw (2) and pull the left front rpm If the left front rpm sensor (L6/1) or right sensor (L6/1) or right front rpm sensor (L6/2) front rpm sensor (L6/2) is seized, cut through out of the upright (3) the electrical line of the left front rpm sensor (L6/1) or right front rpm sensor (L6/2) using suitable pliers. 9 Unscrew bolts (4) and detach brake caliper Attach brake caliper support (5) to

support (5) from steering knuckle (3) suspension strut with cable tie. 10 Remove brake disk (6) 11 Detach tie rod end from upright (3) AR46.40-P-0200-02FF Push transverse control arm on front axle down only as far as required, as otherwise the rubber bushings in the transverse control arm may be damaged. Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.25-p-0400ff, Remove/install steering knuckle MODEL 454.0 with ENGINE 122.9, 134.9, 135.9, 639.9

AR33.25-P-0400SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1579 · Applies to: 453 · AR: AR33.25-P-0400SR, AR42.10-P-0233SR, AR40.20-P-0200SR

Remove/install steering knuckle 24.04.2019 Model 453 Modification notes 23.04.2019 Screw, flange ball joint to steering knuckle, value changed.Operation step 7 BA33.25-P-1001-01F Shown on left side of vehicle on MODEL 453.3 1 Steering knuckle 2 Splash shield 3 Screw 4 Nut 5 Tie rod end 6 Nuts 7 Bolts 8 Nut 9 Screw 10 Flange ball joint L6/1 Left front axle rpm sensor L6/2 Right front axle rpm sensor P33.25-2086-06 Topical note Notes on self-locking nuts and bolts AH00.00-N-0001-01A Notes on repair work on suspension AH00.00-P-0100-01A components Remove/install

1 Remove left or right splash shield (2) of front AR42.10-P-0233SR brake. 2 Remove screw (3). BA42.30-P-1001-01L Bolt, rpm sensor on front axle to steering knuckle 3 Pull left front axle rpm sensor (L6/1) or right front axle rpm sensor (L6/2) out of steering knuckle (1). 4 Unscrew nut (4). BA46.40-P-1001-01F Self-locking nut, tie rod to steering knuckle 5 Press tie rod end (5) off steering knuckle (1) Removal:

with puller and unhook. Carefully pry off tie rod end (5). Otherwise the boot of the tie rod end (5) can be damaged. 450589013300 Puller 6 Counterhold nuts (6) and remove screws (7). BA32.25-P-1003-04Q Bolt of suspension strut to steering knuckle 7 Counterhold nut (8) and remove screw (9). *BA33.25-P-1001-01F Bolt, flange ball joint to steering knuckle 8 Spread steering knuckle (1) with a suitable tool Removal:

and lift off from flange ball joint (10). Loosen steering knuckle (1) carefully from flange ball joint (10). Otherwise the boot of the flange ball joint (10) can be damaged. 9 Install in the reverse order. 10 Perform chassis alignment. AR40.20-P-0200SR Suspension struts Number Designation Model 453 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.25-p-0400sr, Remove/install steering knuckle Model 453

AR33.30-P-0620FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1581 · Applies to: 453 · AR: AR33.30-P-0620FF, AR40.10-P-1100FF, AR26.00-P-0200FF

Remove/install front axle shafts 20.9.10 MODEL 454.0 with ENGINE 134.9, 135.9 Shown on right front axle shaft 1 Front axle shaft 2 Nut 3 Steering knuckle 4 Flange ball joint 5 Transmission P33.30-2064-06 Removing

1.1 Detach wheel cover On vehicles with steel rims. 1.2 Remove front wheels On vehicles with aluminum rims. AR40.10-P-1100FF 2 Clean thread of the front axle shaft (1) with a The thread of the front axle shaft (1) must wire brush and coat a suitable lubricant be free from corrosion and dirt otherwise the front axle shaft (1) may be damaged when unscrewing the nut (2). 3 Remove nut covering (2) in aluminum rim, put On vehicles with aluminum rims. on wheel and screw all way on using two wheel nuts Do not tighten wheel nuts. 4 Lower vehicle On vehicles with aluminum rims. 5 Loosen nut (2) In order to avoid damage to the thread of the front axle shaft (1) the nut (2) should not be released using an impact wrench. The nut (2) must be loosened using a suitable wrench. 6 Remove front wheels AR40.10-P-1100FF 7 Unscrew nut (2) In order to avoid damage to the thread of the front axle shaft (1) the nut (2) should not be released using an impact wrench. The nut (2) must be unfastened using a suitable wrench. If the thread is damaged nevertheless, it should be recut and the front axle shaft (1) replaced if necessary. 8 Drain transmission oil AR26.00-P-0200FF 9 Detach flange joint (4) from steering knuckle AR33.20-P-0446-01FF Push transverse control arm on front axle (3) down only as far as required, as otherwise the rubber bushings in the transverse control arm may be damaged. *454589003300 Puller 10 Pull steering knuckle (3) outwards and press front axle shaft (1) out of the steering knuckle (3) 11 Use a suitable assembly lever to pry off front The front axle shaft (1) must not be pulled axle shaft (1) from transmission (5) out of the transmission (5) at the shaft, otherwise the frictional connection in the joint of the front axle shaft (1) will be destroyed. Install

12 Insert front axle shaft (1) into transmission (5) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.30-p-0620ff, Remove/install front axle shafts MODEL 454.0 with ENGINE 134.9, 135.9

AR33.30-P-0620FG¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1583 · Applies to: 453 · AR: AR33.30-P-0620FG, AR40.10-P-1100FF, AR26.00-P-0200FF, AP18.00-P-0101FB, AR32.35-P-3328FB

Remove/install front axle shafts 20.9.10 MODEL 454.0 with ENGINE 122.950, 639.939 Shown on model 454.034 and removing the right front axle shaft 1 Front axle shaft 2 Nut 3 Screw 4 Steering knuckle 5 Transverse control arm 6 Bearing cap (right only) 7 Bolt (right only) P33.30-2081-06 Removing

1.1 Detach left or right wheel cover on the front On vehicles with steel rims. axle 1.2 Detach left or right wheel on the front axle On vehicles with aluminum rims. AR40.10-P-1100FF 2 Clean thread of the front axle shaft (1) with a The thread of the front axle shaft (1) must wire brush and coat a suitable lubricant be free from corrosion and dirt as otherwise the front axle shaft (1) may be damaged when unscrewing the nut (2). 3 Remove cover of the nut (2) in the aluminum On vehicles with aluminum rims. rim, put on left or right wheel and screw on until it abuts using two wheel nuts 4 Lower vehicle On vehicles with aluminum rims. 5 Loosen nut (2) In order to avoid damage to the thread of the front axle shaft (1) the nut (2) should not be released using an impact wrench. The nut (2) must be loosened using a suitable locking handle. 6 Detach left or right wheel on the front axle AR40.10-P-1100FF 7 Unscrew nut (2) In order to avoid damage to the thread of the front axle shaft (1) the nut (2) should not be released using an impact wrench. The nut (2) must be unscrewed using a suitable locking handle. If the thread is damaged nevertheless, it should be recut and the front axle shaft (1) replaced if necessary. 8 Drain transmission oil AR26.00-P-0200FF 9 Unscrew oil filter With model 454.034 and when removing the AP18.00-P-0101FB right front axle shaft (1). 10 Remove front stabilizer bar link rod On model 454.034 AR32.35-P-3328FB 11 Unscrew bolt (3) and bolt (arrow) on transverse control arm (5) 12 Unscrew bolts (7) and remove bearing cap (6) When removing right front axle shaft (1). Mark installation position of bearing cap (6). 13 Pull steering knuckle (4) outwards and press Push transverse control arm (5) on front front axle shaft (1) out of the steering knuckle axle down only as far as required, as (4) otherwise the rubber bushings in the transverse control arm (5) may be damaged. 14 Lever front axle shaft (1) out of the The front axle shaft (1) may not be drawn transmission using a suitable assembly lever out of the transmission at the shaft, otherwise the friction connection of the joint of the front axle shaft (1) is destroyed. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.30-p-0620fg, Remove/install front axle shafts MODEL 454.0 with ENGINE 122.950, 639.939

Install¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1584 · Applies to: 453 · AR: AR32.35-P-3328FB, AP18.00-P-0101FB, AR26.00-P-0200FF, AR40.10-P-1100FF

15 Plug the front axle shaft (1) into the Check the radial shaft sealing ring of the transmission front axle shaft (1) in the transmission and replace if necessary. 16 Pull steering knuckle (4) outwards and push Push transverse control arm (5) on front the front axle shaft (1) into the steering axle down only as far as required, as knuckle (4) otherwise the rubber bushings in the transverse control arm (5) may be damaged. 17 Mount bearing cap (6) with bolts (7) When installing right front axle shaft (1). Observe installation position of the bearing cap (6). *BA33.30-P-1002-07B

18 Fasten transverse control arm (5) with bolt (3) Replace bolt (3), bolt (arrow) and the nuts. and bolt (arrow) *BA33.15-P-1001-01D

19 Install front stabilizer bar link rod On model 454.034 AR32.35-P-3328FB 20 Mount oil filter With model 454.034 and when removing the AP18.00-P-0101FB right front axle shaft (1). 21 Fill with transmission oil AR26.00-P-0200FF 22 Screw on nut (2) Install new self-locking nut (2). In order to avoid damage to the thread of the front axle shaft (1) the nut (2) should not be screwed-on using an impact wrench. The nut (2) must be screwed-on using a suitable locking handle or torque wrench. 23 Mount the left or right wheel on the front axle AR40.10-P-1100FF Do not mount wheel cover on vehicles with steel rims or cover of nut (2) on vehicles with aluminum rims. 24 Tighten nut (2) In order to avoid damage to the thread of the front axle shaft (1) the nut (2) should not be tightened using an impact wrench. The nut (2) must be tightened using a torque wrench. *BA33.30-P-1001-07B

25.1 Mount left or right wheel cover on front axle Only on vehicles with steel wheels. 25.2 Mount the left or right cover of the nut (2) on Only on vehicles with aluminum rims. the aluminum rim Trailing arms, wishbones

Number Designation Model Model 454.0 with 454.0 with engine engine 122.950 639.939 BA33.15-P-1001-01D Bolt, wishbone to front axle carrier Nm 158 158 Input shaft

Number Designation Engine Engine 122.950 639.939 BA33.30-P-1001-07B Nut, input shaft to wheel bearing Nm 236 235 BA33.30-P-1002-07B Bolt, axle shaft bearing cap Nm 23 25 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.30-p-0620fg, Remove/install front axle shafts MODEL 454.0 with ENGINE 122.950, 639.939

AR33.30-P-0680FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1585 · Applies to: 453 · AR: AR33.30-P-0680FF, AR40.10-P-1100FF, AP18.00-P-0101FB

Remove/install rubber boot at input shaft on transmission side 19.7.06 MODEL 454.0 P33.30-2115-07 Shown on right side on vehicle with engine 135.9 1 Input shaft 3 Hose clamp 5 Rag 2 Rubber boot 4 Hose clamp 6 Inner spider 1 Input shaft 2 Rubber boot 3 Hose clamp 4 Hose clamp 6 Inner spider 7 Bearing 8 Circlip 9 Joint hub P33.30-2116-06 Removal

1 Remove left or right front wheel AR40.10-P-1100FF 2.1 Detach flange ball joint from steering knuckle On engines 134.9 and 135.9 AR33.20-P-0446-01FF *454589003300

2.2 Detach upright from suspension strut On engines 122.9 and 639.9 AR33.25-P-0600-01FF 3 Detach link rod from stabilizer bar Engine 122.9 AR32.35-P-2050-05FB Engine 134.9, 135.9, 639.9 AR32.35-P-2050-05FF 4.1 Remove oil filter On Engine 122.9 Engine oil and filter change AP18.00-P-0101FB

5 Detach clamps (3, 4) 6 Press steering knuckle towards outside, pull Place rags (5) between the upright and drive shaft (1) with inner spider (6) out of joint flange ball joint otherwise the rubber boot of hub (9) and lower the flange ball joint may be damaged. 7 Remove circlip (8). 8 Loosen inner spider (6) from drive shaft (1) Do not damage, disassemble or drop the using suitable tool and take off internal spider (6) and bearing (7) when removing because, if the internal spider (6) or bearing (7) is damaged, the drive shaft (1) must be replaced complete. The bearings (7) remain on the inner spider (6) during removal. 9 Detach rubber boot (2) from drive shaft (1) Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.30-p-0680ff, Remove/install rubber boot at input shaft on transmission side MODEL 454.0

AR33.30-P-0670FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1588 · Applies to: 453 · AR: AR33.30-P-0670FF, AR33.30-P-0680FF

Remove/install rubber boot on drive shaft at outboard end 17.1.06 MODEL 454.0 Shown on right-hand side of vehicle with engine 135.9 1 Boot 2 Vibration damper (on engines 134.9 and 135.9) 3 Hose clamp (on engines 134.9 and 135.9) 4 Rubber boot 5 Drive shaft P33.30-2117-01 Shown on right-hand side of vehicle with engine 135.9 1 Boot 5 Drive shaft 6 Constant velocity joint 7 Hose clamp 8 Hose clamp P33.30-2114-06 Remove

1 Remove rubber boot (4) from drive shaft (5) at AR33.30-P-0680FF transmission end 2.1 Detach hose clamp (3) from vibration damper When removing the right drive shaft (5) on (2) vehicles with engines 134.9, 135.9. 3.1 Mark position of vibration damper (2) and When removing the right drive shaft (5) on spray drive shaft (5) with suitable grease at vehicles with engines 134.9, 135.9. transmission end 4.1 Pull vibration damper (2) off drive shaft (5) When removing the right drive shaft (5) on vehicles with engines 134.9, 135.9. 5 Detach hose clamps (7, 8) 6 Cut open boot (1) and pull off 7 Clean constant velocity joint (6) and drive shaft (5) Install

8 Spray drive shaft (5) with suitable grease and The boot (1) must not be damaged when it push new boot (1) with hose clamps (7, 8) is pushed onto the drive shaft (5) otherwise onto drive shaft (5) dirt will enter the constant velocity joint (6) and cause irreparable damage. Helper required 9 Fill boot (1) and constant velocity joint (6) with Use the grease tubes with the blue the grease included in the package marking. 10 Align drive shaft (5) straight with constant Ensure that the hose clamps (7, 8) are velocity joint (6), position boot (1) on constant properly seated. velocity joint (6) and fasten hose clamps (7, 8) *WH58.30-Z-1011-02A

11 Lower drive shaft (5) downwards Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.30-p-0670ff, Remove/install rubber boot on drive shaft at outboard end MODEL 454.0

Spray drive shaft (5) with suitable grease and When installing the right drive shaft (5) on¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1589 · Applies to: 453 · AR: AR33.30-P-0680FF

12.1 Spray drive shaft (5) with suitable grease and When installing the right drive shaft (5) on push vibration damper (2) onto drive shaft (5) vehicles with engines 134.9, 135.9. as far as the marking made during removal 13.1 Attach hose clamp (3) to vibration damper (2) When installing the right drive shaft (5) on vehicles with engines 134.9, 135.9. 14 Install new rubber boot (4) on drive shaft (5) at AR33.30-P-0680FF A new rubber boot (4) is included with the transmission end boot (1). Commercially available tools Number Designation WH58.30-Z-1011-02A Clamping pliers Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.30-p-0670ff, Remove/install rubber boot on drive shaft at outboard end MODEL 454.0

BE35.00-Z-9999CZ¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1592 · Applies to: 453 · AR: BE35.00-Z-9999CZ

Test and adjustment values: Smart: Rear axle 18.09.2019 MODEL all Trailing arm, wishbone MODEL 451 BE35.15-P-1000-01B Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be35.00-z-9999cz, Test and adjustment values: Smart: Rear axle MODEL all

AR35.10-P-0070SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1594 · Applies to: 453 · AR: AR35.10-P-0070SR

Remove/install axle tube 12.8.15 Model 453 Shown on left side of vehicle 1 Rear axle tube 2 Rubber grommet 3 Brake cable 4 Brake cover plate 5 Guide 6 Guide P35.10-2478-06 P35.10-2479-09 1 Rear axle tube 9 Electrical line 12 Brake hoses 7 Grommets 10 Bracket L6/3x1 Left rear axle rpm sensor electrical connector 8 Electrical line 11 Brake lines L6/4x1 Right rear axle rpm sensor electrical connector Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar35.10-p-0070sr, Remove/install axle tube Model 453

Do not detach the threaded fastenings of¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1596 · Applies to: 453 · AR: AR35.30-P-0620SR, AR35.30-P-0620SRA, AR00.60-P-0100SR, AR42.10-P-0010SR, AR40.20-P-0200SR

the control arms (16) with the rear axle cross member (15) and the rear axle tube (1). 12 Remove rear axle shafts (17) from wheel Model 453 with transmission 700.12 AR35.30-P-0620SR bearings and fasten using welding wire to suitable position above rear axle tube (1) Model 453 with transmission 700.41 AR35.30-P-0620SRA

Secure ball joints of rear axle shafts (17) against excessive bending or stretching. Otherwise, the ball joints on the rear axle shafts (17) may be damaged. Do not detach rear axle shafts (17) at

transmission end. 13 Secure vehicle on vehicle lift AR00.60-P-0100SR 14 Prop up rear axle tube (1) using major assembly lifting platform 000 588 03 62 00 Lifting platform WS01.00-P-0091A

Position the major assembly lifting platform

so that a telescopic lifter can be positioned in the rear axle center bearing (18) area. 15 Prop up rear axle tube (1) using telescopic lifter in area of rear axle center bearing (18) 000 588 11 62 00 Major assembly mount WS01.00-P-0092B

16 Remove bolt (19) *BA35.10-P-1002-03B Bolt, rear axle tube to body 17 Lower rear axle tube (1) using major assembly lifting platform or telescopic lifter far enough to enable the rear axle springs (20) to be removed, and so that the rear axle tube (1) is completely on the major assembly lifting platform 000 588 03 62 00 Lifting platform WS01.00-P-0091A

Continually check position of brake lines (11), brake hoses (12) and electrical lines (8, 9) when lowering or lifting rear axle tube (1). Otherwise, these may be damaged through kinking, crushing or shearing off. The brake cables (3) should be taken out

of the lowering or lifting area when lifting or lowering the rear axle tube (1). 18 Lower the major assemblies lifting platform with the rear axle tube (1) and pull forward under the vehicle 000 588 03 62 00 Lifting platform WS01.00-P-0091A

19 Install in the reverse order 20 Bleed brake system AR42.10-P-0010SR 21 Perform wheel alignment check AR40.20-P-0200SR Rear axle shock absorber Number Designation Model 453 BA32.25-P-1001-03Q Bolt, shock absorber to rear axle Nm 105 Rear axle Number Designation Model 453 BA35.10-P-1002-03B Bolt, rear axle tube to body Nm 180 Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar35.10-p-0070sr, Remove/install axle tube Model 453

AR35.10-P-0010FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1597 · Applies to: 453 · AR: AR35.10-P-0010FF, AR40.10-P-1100FF, AR42.10-P-0170FG

Remove/install complete rear axle 20.3.06 MODEL 454.0 Shown on vehicle with code (30Y) Rear axle disk brake 1 Clamp 2 Bolt 3 Electrical line 4 Handbrake cable 5 Rear axle 6 Brake hose L6/3 Left rear rpm sensor L6/4 Right rear rpm sensor P35.10-2248-06 Shown on vehicle with code (30Y) Rear axle disk brake 5 Rear axle 7 Nut 8 Removal fixture

9 Belt

10 Bolts 11 Bolts 12 Wheel bearing 13 Brake anchor plate 14 Brake caliper support (with code (30Y) Rear axle disk brake) 15 Brake disk (with code (30Y) Rear axle disk brake) 16 Brake caliper (with code (30Y) Rear axle disk brake) P35.10-2249-06 Remove/install

1 Remove the rear wheels AR40.10-P-1100FF 2 Remove clamp (1) and remove brake hose (6) out of the bracket on the left and right of the rear axle (5) 3 Unscrew the bolts (2) on the left and right and Installation:

Replace sealing rings and pull out left rear rpm sensor (L6/3) and right bolts (2). rear rpm sensor (L6/4) *BA42.30-P-1001-02E

4 Remove electrical line (3) and hand brake cables (4) on the left and right of the rear axle (5) 5.1 Remove brake pads on rear axle On vehicles with code (30Y) Rear axle disk AR42.10-P-0170FG brake Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar35.10-p-0010ff, Remove/install complete rear axle MODEL 454.0

Fasten left and right brake caliper (16) at the On vehicles with code (30Y) Rear axle disk¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1598 · Applies to: 453 · AR: AR35.20-P-0302FF, AR32.20-P-0230FF

6.1 Fasten left and right brake caliper (16) at the On vehicles with code (30Y) Rear axle disk nuts (7) with cable ties brake 6.2 Remove left and right wheel bearing (12), On vehicles without code (30Y) Rear axle disk AR35.20-P-0302FF secure brake carrier plates (13) and brake detachable parts with cable ties to prevent them from falling down Ensure that the brake lines are not damaged due to kinking otherwise they must be replaced. 7 Position removal fixture (8) under the rear The main lifters from the companies axle (5) Mazzola and AS Hydraulic can be used according to choice. *450589026200

WH58.30-Z-1011-07A Main lifter Co. Mazzola WH58.30-Z-1011-07A Main lifter Fa. AS Hydraulic 8 Use belt (9) to secure rear axle (5) *450589026200

WH58.30-Z-1011-07A Main lifter Co. Mazzola WH58.30-Z-1011-07A Main lifter Fa. AS Hydraulic 9 Remove rear springs AR32.20-P-0230FF 10 Unscrew bolts (10) on left and right sides Installation: Replace self-locking bolts

(10). Installation:

Fit bolts (10) and then tighten them. *BA35.10-P-1001-03A

11 Lower rear axle (5) and detach from the Helper required removal fixture (8) *450589026200

WH58.30-Z-1011-07A Main lifter Co. Mazzola WH58.30-Z-1011-07A Main lifter Fa. AS Hydraulic 12.1 Unscrew bolts (11) and remove wheel bearing When replacing the rear axle (5) on vehicles (12) with brake carrier plate (13), brake caliper with code (30Y) Rear axle disk brake support (14) and brake disk (15) Installation: Replace self-locking bolts

(11). Installation:

The pressed-in arrow on the wheel bearing (12) must point in the direction of travel. *BA35.20-P-1001-06B

13 Install in the reverse order Rear axle carrier

Number Designation Model 454.0 BA35.10-P-1001-03A Bolt, rear axle to body Nm 93 Hub

Number Designation Model 454.0 BA35.20-P-1001-06B Bolt, hub to rear axle Nm 70 Rear axle rpm sensor

Number Designation Model 454.0 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar35.10-p-0010ff, Remove/install complete rear axle MODEL 454.0

AR35.15-P-0204SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1600 · Applies to: 453 · AR: AR35.15-P-0204SR, AR40.10-P-1100SR

Remove/install control arm 04.08.2014 MODEL 453 P35.15-2024-09 Shown on MODEL 453.3 1 Control arm 5 Threaded rod 9 Nuts 2 Guide pin 6 Nut 10 Bolts 3 Screw 7 Rear axle crossmember a Clearance 4 Screw 8 Screw Risk of death Danger ! caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Notes on repair work on suspension AH00.00-P-0100-01A

components Remove

1 Detach rear complete wheels AR40.10-P-1100SR 2 Remove screws/bolts (3) Do not unscrew bolts (4).

3 Screw nuts (6) and shims onto suitable Threaded rods (5) or bolts with a minimum

threaded rods (5) length of 200 mm are to be used. 4 Screw threaded rods (5) into threaded holes for bolts (3) 5 Adjust distance dimension (a) by turning the Distance dimension (a): approx. 25 mm

nuts (6) 6 Remove bolts (4) alternately Otherwise the rear axle crossmember (7)

may become tilted on the threaded rods (5). 7 Lower rear axle crossmember (7) by

unfastening nuts (6) until it is free of tension When lowering the rear axle crossmember (7) make sure that it does not come into contact with the transmission housing. Otherwise this can lead to paint damage and corrosion on the rear axle crossmember (7). 8 Unscrew left or right bolt (8) 9 Unscrew left or right nut (9) and remove washer 10 Pull out left or right bolt (10) and remove left or right control arm (1) Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar35.15-p-0204sr, Remove/install control arm MODEL 453

AR35.20-P-0302FF¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1607 · Applies to: 453 · AR: AR35.20-P-0302FF, AR42.10-P-0240FF, AR42.10-P-1010FF

Remove/install wheel bearing 20.3.06 MODEL 454.0 Shown on vehicle with code (30Y) Rear axle disk brake 1 Bolt 2 Bolts 3 Wheel hub with wheel bearing 4 Anchor plate L6/3 Left rear rpm sensor L6/4 Right rear rpm sensor P35.20-2153-06 Remove/install

1.1 Remove rear axle brake disk On vehicles with code (30Y) Rear axle disk AR42.10-P-0240FF brake 1.2 Remove brake drum On vehicles without code (30Y) Rear axle disk AR42.10-P-1010FF brake 2 Unscrew bolt (1) Installation:

Install new self-locking bolt (1) *BA42.30-P-1001-02E

3 Pull out the left rear left rear rpm sensor (L6/3) Installation:

Replace sealing ring on left or right rear rpm sensor (L6/4) rear rpm sensor (L6/3) or right rear rpm sensor (L6/4). 4 Remove bolts (2) Installation: Replace self-locking bolts

(2). *BA35.20-P-1001-06B

5.1 Remove wheel hub with wheel bearing (3) On vehicles with code (30Y) Rear axle disk and anchor plate (4) brake Installation:

The arrow pressed onto the wheel hub with wheel bearing (3) has to point into the direction of travel. 5.2 Remove wheel hub with wheel bearing (3) On vehicles without code (30Y) Rear axle disk brake Secure the anchor plate (4) to prevent it from falling, otherwise the brake line may be damaged. Installation:

The arrow pressed onto the wheel hub with wheel bearing (3) has to point into the direction of travel. 6 Install in the reverse order Hub

Number Designation Model 454.0 BA35.20-P-1001-06B Bolt, hub to rear axle Nm 70 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar35.20-p-0302ff, Remove/install wheel bearing MODEL 454.0

AR35.20-P-0302SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1609 · Applies to: 453 · AR: AR35.20-P-0302SR, AR42.10-P-1010SR

Remove/install wheel bearing 04.08.2014 MODEL 453 Shown on left side of vehicle with removed rear axle shaft, MODEL 453.3 1 Wheel bearings 2 Bolts 3 Brake cover plate 4 Brake line P35.20-2337-06 Shown on left side of vehicle 5 Screw 6 Rear axle shaft 7 Puller 7.1 Threaded rods 7.2 Spindle P35.20-2340-04 Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Remove

1 Remove left or right brake drum AR42.10-P-1010SR 2 Remove screw (5) To release the bolt (5) screw two wheel

bolts into the wheel hub and counterhold wheel hub using suitable tool. 3 Unscrew bolts (2) of wheel bearing (1)

Secure brake cover plate (3) against moving. Otherwise, the brake line (4) may bend and it will have to be replaced. 4 Position commercially available puller (7) on wheel hub to match the hole circle and secure by screwing-in the threaded rods (7.1) 5 Screwing in the spindle (7.2) detaches the wheel hub with wheel bearing (1) from the rear axle shaft (6) Install

6 Slide wheel bearing (1) onto rear axle shaft The gearing of the rear axle shaft (6) must

(6) line up with that of the wheel bearing (1). 7 Align brake cover plate (3) and wheel bearing (1) to match hole pattern on axle tube and screw-in bolts (2) by several turns 8 Tighten screw/bolts (2) *BA35.20-P-1001-07E Bolt, wheel bearing to rear axle tube Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar35.20-p-0302sr, Remove/install wheel bearing MODEL 453

AR35.30-P-0620SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1611 · Applies to: 453 · AR: AR35.30-P-0620SR, AR40.10-P-1100SR, AR26.00-P-0200SR, AR35.15-P-0250SR, AR26.40-P-0339SR

Remove/install rear axle shaft 11.2.15 MODEL 453 with TRANSMISSION 700.12 P35.30-2166-09 Shown on left rear axle shaft (1) 1 Rear axle shaft 3.2 Spindle 7 Slide hammer puller 2 Bolt 4 Rear axle cross member 8 Extraction tool 3 Puller 5 Control arm 3.1 Threaded rods 6 Axle tube Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Remove

1 Remove left or right rear wheel AR40.10-P-1100SR 2 Drain transmission oil AR26.00-P-0200SR 3 Unscrew bolt (2) 4 Lower rear axle cross member (4) until it is AR35.15-P-0250SR unstressed Do not release the bolted connections on

the control arms (5). 5 Position commercially available puller (3) on the wheel hub to match the hole circle and tighten with the threaded rods (3.1) 6 By screwing in the spindle (3.2) release the

rear axle shaft (1) from the wheel hub and Secure ball joints of rear axle shaft (1) against move out excessive bending or pulling apart. Otherwise, the ball joints on the rear axle shaft (1) may be damaged. The axle tube (6) can be moved slightly

sidewards to create the necessary space for extending the rear axle shaft (1). 7 Remove puller (3) 8 Using impact extractor (7) and puller tool (8) Helper required.

to pull rear-axle shaft (1) out of transmission and pull out Position the

puller tool (8) to match the contour of the rear axle shaft (1) (arrow A). 221589043300 Extraction tool 602589003300 Impact extractor 9 Remove radial shaft sealing ring AR26.40-P-0339SR Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar35.30-p-0620sr, Remove/install rear axle shaft MODEL 453 with TRANSMISSION 700.12

AR35.30-P-0620SRA¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1613 · Applies to: 453 · AR: AR35.30-P-0620SRA, AR40.10-P-1100SR, AR27.00-P-0001SR, AR35.15-P-0250SR

Remove/install rear axle shaft 07.06.2017 Model 453 with transmission 700.41 P35.30-2170-09 1 Rear axle shaft 3.2 Spindle 7 Slide hammer puller 2 Screw 4 Rear axle cross member 8 Pulling device 3 Puller 5 Control arm 3.1 Threaded rods 6 Axle tube Risk of injury Wear protective gloves, protective clothing Caution to skin and eyes due to AS00.40-Z-0001-01A

handling of transmission oil. Health risk and safety glasses. caused by swallowing transmission oil Do not pour transmission oil into beverage bottles. Topical note Notes on threaded connections fastened using AH00.00-P-0020-01A a tightening angle-based tightening process Topical note Notes on self-locking nuts and bolts AH00.00-N-0001-01A Remove

1 Remove left or right rear wheel AR40.10-P-1100SR 2 Remove wheel trim cap from left or right rear Model 453 with transmission 700.41 except code R82 (38.1 cm (15") steel wheels wheel with hubcaps) except code R83 (38.1 cm (15") steel wheels with hubcaps) 3 Drain transmission oil AR27.00-P-0001SR 4 Unscrew bolt (2) 5 Lower cross member on rear axle (4) until it is AR35.15-P-0250SR tension free Do not release the bolted connections on

the control arms (5). 6 Position commercially available puller (3) on the wheel hub to match the hole circle and tighten with the threaded rods (3.1) 7 Screw in the spindle (3.2) to release rear axle

shaft (1) from the wheel hub and extend it Secure ball joints of rear axle shaft (1) against excessive bending or pulling apart. Otherwise, the ball joints on the rear axle shaft (1) may be damaged. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar35.30-p-0620sra, Remove/install rear axle shaft Model 453 with transmission 700.41

AR35.30-P-0626SR¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1615 · Applies to: 453 · AR: AR35.30-P-0626SR, AR35.30-P-0620SR, AR35.30-P-0620SRA

Remove/install rear axle shaft boot at wheel side 25.09.2018 Model 453 P35.30-2167-09 1 Rear axle shaft boot 3 Clip 6 Constant velocity joint 1.1 Ridge 4 Clip 6.1 Groove 2 Rear axle shaft 5 Constant velocity joint hub 7 Retaining ring Remove

1 Remove right or left rear axle shaft (2) Model 453 with transmission 700.12 AR35.30-P-0620SR Model 453 with transmission 700.41 AR35.30-P-0620SRA Disassemble

2 Clamp right or left rear axle shaft (2) in vise 3 Remove clamp (3) 4 Remove clamp (4) 5 Cut open rear axle shaft boot (1) 6 Detach boot from rear axle shaft (1) 7 Position suitable drift onto constant velocity

joint hub (5) and drive constant velocity joint The drift may only be positioned, as shown, on (6) off the rear axle shaft (2) by applying the bar of the constant velocity joint hub (5) specific hammer impacts to it (arrow A). Otherwise, the constant velocity joint (6) may be damaged. 8 Remove retaining ring (7) Clean

9 Clean constant velocity joint (6)
10 Clean rear axle shaft (2) in gearing area Assemble

11 Slide clamp (3) onto rear axle shaft (2) 12 Slide new boot for rear axle shaft (1) onto rear axle shaft (2)
13 Install new retaining ring (7) 14 Pack grease included in scope of supply, into Make sure that sufficient grease is in the

constant velocity joint (6) level with upper edge constant velocity joint (6) bearing. of constant velocity joint hub (5) 15 Slide constant velocity joint (6) onto rear axle The constant velocity joint (6) must be

shaft (2) latched into place by the retaining ring (7). Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar35.30-p-0626sr, Remove/install rear axle shaft boot at wheel side Model 453

Fill rear axle shaft boot (1) and constant¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1616 · Applies to: 453 · AR: AR35.30-P-0620SR, AR35.30-P-0620SRA

16 Fill rear axle shaft boot (1) and constant velocity joint (6) with remaining quantity of grease 17 Slide boot for rear axle shaft (1) onto constant

velocity joint (6) Make sure that the boot for the rear axle shaft (1) is not compressed or stretched. Otherwise, this may lead to premature wear or to a defect. The raised bead (1.1) of the boot for the

rear axle shaft (1) must be located in the groove (6.1) of the constant velocity joint (6). 18 Position clamp (3) onto boot for rear axle shaft (1) and fasten in place using a suitable pair of pliers, by compressing the clamp profile 19 Position clamp (4) on boot for rear axle shaft (1), clamp and latch into place using suitable pliers (arrows B) Install

20 Install right or left rear axle shaft (2) Model 453 with transmission 700.12 AR35.30-P-0620SR Model 453 with transmission 700.41 AR35.30-P-0620SRA Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar35.30-p-0626sr, Remove/install rear axle shaft boot at wheel side Model 453

Model 204¶

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1632 · Applies to: 453 · AR: AP33.20-P-3353CW, AP33.20-P-3353BP, AP33.20-P-3353BA, AP33.20-P-3353AK, AP35.20-P-3555RQ (+1 more)

AP33.20-P-3353CW

Model 207 Model 203, 209 AP33.20-P-3353BP

Model 129, 140, 170, 202, 208, 210, 215, 220, AP33.20-P-3353BA

230 Model 211.004/006/007/008/016/020/022/023/024/02 6/028/029/041/042/052/054/056/057/061/065/ 070/072/076/077/080/082/083/084/087/089/09 0/092/206/207/208/216/220/222/223/226/241/ 242/252/254/256/257/261/265/270/272/276/27 7/280/282/283/284/287/289/290/292/606/608/ 616/620 Model 117, 156, 176, 242, 246 AP33.20-P-3353AK

Model 169.006/007/008/031/032/033/034/090 Model 169.306/307/308/331/332/333/334 Model 245.207/208/231/232/233/234 9 Check rear axle ball joint for play and seal bellows for damage Model 166, 292 AP35.20-P-3552E

Model 190 AP35.20-P-3552D

Model 117, 156, 176, 242, 246 AP35.20-P-3552B

Model 217, 222 AP35.20-P-3552C

Model 453 AP35.20-P-3552S

Model 197.3/4 AP35.20-P-3555RQ

Model 163.1 AP35.20-P-3555GH

10 Check condition of shock absorbers and springs Model 166, 292 AP32.25-P-3255D

Model 190 AP32.25-P-3255C

Model 217, 222 AP32.25-P-3255B

except code 487 (Active Body Control (ABC)) Model 453 AP32.25-P-3255S

Model 117, 156, 176, 242, 246 AP32.25-P-3255A

11 Drive the vehicle onto the measuring station The vehicle lift must be horizontal on the

and secure using the parking brake measuring station. 12 Unlock turnplates and sliding platforms 13 Move vehicle to driving level Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar40.00-p-0202a, General information on vehicle level measurement Model 117, 129, 140, 156, 163, 166, 168, 169, 170, 171, 172, 176, 190, 197, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 222, 230, 231, 242, 245, 246, 292, 451, ...