I just returned from a trip to Florida in my '84 300D and some problems popped up along the way. The most troubling is I replaced the CV axles before I left and they didn't quite tighten up correctly when installed. The bolts I am refering to are the 8mm bolts that retain the outer portion of the axle to the wheel hub. The 8mm bolts have a washer and a sleeve that they pass through and then into the splined shaft end of the axle. The washer places the load on the bearing hub and the sleeve, I assume is there to prevent over tightening. Problem is the washers are slightly deformed, inwards from previous axle installs and the result was they did not pull the splined section of the axle into the wheel hub firmly allowing the outer section of the axles considerable freedom of movement. They can be easily grabbed and wobbled around. The sleeve on the 8mm bolt made it seem like the bolt was plenty tight and it was but since the washers weren't making contact the axles were loose. Loose for @1700miles.... I discovered this in D.C. on my way home while looking for another noise. I ended up flipping the washers over so that tightening the 8mm bolts would cause them to deform in the other direction but press on the wheel bearing hub enough to keep the axles tight and get me home. I am dreading taking the axles/hubs apart and finding damage to the splines.... So damage not withstanding I am planning on changing the mickey-mouse washers out to custom washers from 1/4" plate steel and longer 8mm grade 8 bolts without the sleeves to make sure the washers press on the hubs and positively retain the axles. Anyone see a problem with this? I can't see how the original thin steel washer and sleeve setup was supposed to survive repeated removal and installation without this happening. Any input would be great. Thanks, RT

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84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K

Just what noise was it making? I'm wondering since I just replaced my axles and have a strange clunking under certain conditions whether I got a bad axle, or might be experiencing the same problem..

Actually, the noise was exacerbated by the very harsh shifting caused by a vacuum leak that probably didn't help the axles at all. If you grab the outer section and try to move it it shouldn't move at all. There was plenty of clunking and banging when the shifts happened and that all but went away when I flipped the washers and it tightened the shafts. RT

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When all else fails, vote from the rooftops!
84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K

Here is what the W123 service manual has to say about that washer:

Attention!
Replace lock washer after one-time use.

The service manual also warns about the possibility of incorrect combinations of parts as there were three different versions of of the bolt/spacing sleeve.

TangoFox is correct about them being one time use....
But it may not have been deformed.....I think you are looking at a " Bell" washer... like is used under the head bolts on small engines.... to keep the pressure applied.... So it is a round spring and not meant to be flat.
Did you use a torque wrench to apply the pressure ? If you did then maybe the wheel was on the ground and added resistance to inward travel causing your readings to get high before the proper force had reached the bolt.

The washers are not the spring type "belleville" I think they are called? Not them. Just a standard sheetmetal type that is deformed in the normal process of tightening the retaining bolts. No I did not use a torque wrench but the retaining bolt definitely bottomed on the steel sleeve so the amount of torque is a moot point. The washers were bent and not putting pressure on the bearing hub regardless of how tight the bolt was. I cannot find the washer avavilable on Fastlane or PP. Maybe will try dealer. RT

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When all else fails, vote from the rooftops!
84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K

"Just a standard sheetmetal type that is deformed in the normal process of tightening the retaining bolts."

That is a little unusual isn't it ?

Leathermang,
The whole retention setup is a little odd. The wheel bearing hubs are splined to accept the outer section of the axle. After the splined section they open up to @ 1.25" bore. The 8mm bolt is literally floating in the center of bore, inside the steel sleeve. The only contact with the hub is the outer edge of the washer. The washer is a large washer like a fender washer and just as thin. Since it only makes contact on the very outside of the washer and the bolt is pulling on the center until the bolt tightens down on the sleeve it distorts the washer quite easily. I am assuming this is how it is supposed to be and why the washers are one time use only. Yes I find this strange since all other CV type axles I have ever seen use a fairly substantial retaining nut/bolt under equally substantial torque to retain them to the hub. I am wondering if a standard steel fender washer of the appropriate size would be a substitute since I haven't found the correct washers in my limited searches. RT

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When all else fails, vote from the rooftops!
84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K

I just looked at the manual...
First it shows using a substantial tool to pull the axle into the hub...
Then they call for 30 NM of torque to be applied...
and call that washer a " clamping washer"....
Interpretation of the " English" in these manuals is not a sure thing.... Do they mean just a washer or do they mean one which maintains ' clamping ' pressure on the axle shaft ?

OK, after rereading your original post I am not sure which parts you are talking about..
If you are talking about the bolts which would be keeping the tapered roller bearings in place then the chances that they are spring type washers if greater since tapered roller bearings are normally preloaded... If you are just talking about the axle nut then I don't know... except that they call that one a ' clamping washer'...

when i redid my chassis the dealer hooked me up with all the hardware i needed...at a great cost...and i too read that that washer was a one time use...after taking it out i think we can all see that...

good luck
jake

Interestingly enough. an earlier version used a 12mm bolt without the sleeve, and a very thick washer. MB then went to the 8mm bolt with sleeve and the thin washer. Sounds like the "improved" version might not be.

The washer is not likely to be bent if the axle shaft is fully seated in the hub prior to installation of the bolt/sleeve. However, if the bolt is utilized to pull the axle shaft into the hub, the washer is much more likely to bend. If the shaft is seated first, the washer bottoms out on the sleeve, and there is little bending force applied.

Tangofox,
Thanks for the info on the 12mm version. It sounds like the thicker washer, beefier bolt idea of mine would work fine. Incidentally, using the bolt to pull the axle in is not a big deal. The splines slide easily together so it takes very little force to pull the axle in. I have concluded that the washer is intended to deform on installation to provide the correct preload retention to the axle. I am looking for the correct washers as the easiest solution. RT

__________________
When all else fails, vote from the rooftops!
84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K

call me crazy - but to install 12mms wouldnt you need the 12mm axle?
id think so -
jake

Okay, your crazy! Actually when I say beefier bolt I mean a better grade like a grade 8 bolt and thicker washer, but still the 8mm. RT

__________________
When all else fails, vote from the rooftops!
84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K

Grade 8 is an SAE specification and does not apply to metric bolts. Your looking for a Class 8.8 or 10.9, DIN 931 or 933. Good luck at the hardware counter... McMaster Carr has them though.

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Bill Reimels
Now down to one:
1972 300SE 3.5 W109 (Euro delivery)