Remove/install transfer case

AR28.10-P-0100I

Remove/install transfer case

2.11.11

31.1.06

Transmission oil, Specifications for Operating Fluids

*BF28.10-P-1001-01D



Removing

1

Open engine hood

AR88.40-P-1000M

2

Remove hot film mass air flow sensor

AR07.07-P-1454AA

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

3

Raise vehicle with vehicle lift

4

Detach lower engine compartment paneling

AR61.20-P-1105M

5

Detach exhaust shielding plate (41) for front propeller shaft behind transfer case (16)

6

Remove exhaust bracket (44)

7

Detach transmission ground (W49) from transfer case (16)

8

Remove right O2 sensor downstream of CAT (G3/6)

AR14.00-P-5303AA

9

Mark propeller shaft (70) of front axle gear relative to flange of transfer case (16)

10

Detach propeller shaft (70) of front axle gear on transfer case (16)

11

Detach front propeller shaft from flange on transfer case (16)

 The flexible coupling remains on the propeller shaft.

12

Loosen fitted sleeves of flexible coupling and push back propeller shaft

If the fitted sleeves are jammed: 

AR41.10-P-0050-09I



Prepare drift for loosening fitted sleeves in flexible couplings.

WF58.50-P-4110-01A

13

Unhook shift rod (50) at automatic transmission (17)

 To unhook, press the locking device (50a) upwards until the bolt of the shift rod (50) can be moved out.

14

Detach reinforcement bridge (49)

15

Unhook rear exhaust system (48) from the exhaust rubber mounts, lower slightly and tie securely

16

Support automatic transmission (17) with transmission jack and transmission platform

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

Telescopic transmission jack

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

17

Remove rear engine crossmember (42)

See: 

Remove rear engine mount.

AR22.10-P-1160IW

18

Slightly lower automatic transmission (17)

19

Detach transfer case (16) from automatic transmission (17)

 Four nuts and seven bolts



Install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

20

Coat plug-type splines in transfer case (16) with grease

Klueber Microlube GNY 202

*BR00.45-Z-1071-06A

21

Mount transfer case (16) to automatic transmission (17)

 Both centering sleeves (arrows) have to be firmly seated in the automatic transmission (17), if necessary replace centering sleeves.

 Four nuts and seven bolts



*BA28.10-P-1001-01C

22

Check oil level in transfer case (16), correct if necessary

AR28.10-P-1000-26I

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

Telescopic transmission jack

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

 Transfer case filling capacity

*BF28.10-P-1001-01D

 Oil filler opening screw plug

*BA28.10-P-1004-01C

 Inspection hole screw plug

*BA28.10-P-1005-01C

23

Install rear engine crossmember (42)

See: 

Install rear engine mount.

AR22.10-P-1160IW

24

Remove transmission jack and transmission platform

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

Telescopic transmission jack

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

25

Attach rear exhaust system (48) to the exhaust rubber mounts

26

Attach stiffening bridge (49)



*BA61.10-P-1002-01D

27

Attach front propeller shaft to flange of transfer case (16)

AR41.10-P-0050-07I



*BA41.10-P-1001-01A

28

Attach transmission ground (W49) at transfer case (16)

29

Attach exhaust shielding plate (41) for front propeller shaft behind transfer case (16).

30

Mount exhaust bracket (44)

 Check tapping plates (44a), replace if necessary.

31

Install right O2 sensor downstream of TWC [KAT] (G3/6)

AR14.00-P-5303AA

32

Attach propeller shaft (70) of front axle gear to flange of transfer case (16)

 Observe marking.



*BA33.30-P-1005-02C

33

Hook in shift rod (50) on automatic transmission (17)

34

Install lower engine compartment paneling

AR61.20-P-1105M

35

Install hot film mass air flow sensor

AR07.07-P-1454AA

36

Close engine hood

AR88.40-P-1000M

Number

Designation

Model
220.08/18
except model 220.087/187

Model
220.087/187

BA28.10-P-1001-01C

Nut and bolt, transfer case to automatic transmission

Nm

25

25

BA28.10-P-1004-01C

Oil filler opening screw plug

Nm

30

30

BA28.10-P-1005-01C

Inspection hole screw plug

Nm

30

30

Number

Designation

Model
220.08/18

BA33.30-P-1005-02C

Bolt of front axle gear propeller shaft to transfer case flange

M8

Stage 1

Nm

15

Stage 2

°

30

M10

Stage 1

Nm

-

Stage 2

°

-

Number

Designation

Model
220

BA41.10-P-1001-01A

Self-locking nut, flexible coupling to transmission or front propeller shaft

M10

Nm

-

M12

Nm

60

Number

Designation

Model 220

BA61.10-P-1002-01D

Collar bolt, rear reinforcement bridge to frame floor

Nm

23

Number

Designation

Model
220.083/084/
087/183/184/187

BF28.10-P-1001-01D

Gear oil

Filling capacity

Liters

0,59

Specifications for Operating Fluids

Sheet

BB00.40-P-0236-13A

Number

Designation

Order number

BR00.45-Z-1071-06A

Klueber Microlube GNY 202

A 001 989 44 51 10