Disassemble/assemble transfer case

AR28.10-P-1000A

24.11.08

MODEL 460, 461 with TRANSFER CASE 750.60

P28.10-2132-06

1 Nut

2 Connector flange

3 Inner radial shaft sealing ring

4 Outer radial shaft sealing ring

5 Cover

6 Spacer tube

7 Gasket

8 Tapered roller bearing

9 Spacer washer

10 Gear

11 Spacer washer

12 Needle roller bearing

13 Shift sleeve

14 Spacer washer

15 Gear

16 Cylindrical roller bearing

17 Driver

18 Nut

19 Connector flange

20 Outer radial shaft sealing ring

21 Inner radial shaft sealing ring

22 Input shaft cover

23 Gasket

24 Oil drain plug

25 Housing

26 Oil baffle plate

27 Cover

28 O-ring

29 Gasket

30 Centering pin

31 Rear bearing cap

32 Oil filler plug

33 Spacer ring

34 Ball bearing

35 Spacer tube

36 Needle roller bearing

37 Input shaft

38 Circlip

39 Ball bearing

40 Spacer tube

41 Shift sleeve

42 Washer

60 Circlip

61 Ball bearing

62 Spacer ring

63 Radial shaft seal

64 Radial shaft seal

65 Connector flange

66 Nut

67 Bearing bracket

68 Shift fork

69 Stud bolt

70 Nut

71 Transmission housing cover

72 Gasket

43 Shift dog

44 Synchronizer ring

45 Synchronizer body ball

46 Synchronizer body

47 Spring

48 Ball stud

49 Synchronizer slide collar

50 Synchronizer ring

51 Spacer tube

52 Synchronizer ring

53 Gear

54 Thrust washer

55 Woodruff key

56 Tapered roller bearing

57 Spacer washer

58 Intermediate flange

59 Spacer ring

	Disassemble
1	Clamp transfer case to assembly stand		AR28.10-P-1000-16A
			*460589003100
2	Remove coupling flange (2, 19, 65)		AR28.10-P-1000-09A
		 Socket	*001589160900
		 Retainer wrench	*460589013100
		 Puller	*460589023300
		 Pressure screw M 8	*460589003500
3	Remove radial shaft sealing rings (3, 4, 20, 21) from output flange to front axle		AR28.10-P-4075A
4	Remove radial shaft sealing rings (63, 64) from output flange to rear axle		AR28.10-P-4150A
5	Remove speedometer drive		AR28.40-P-1001A
6	Remove rear bearing cap (31)		AR28.40-P-1500A
7	Disassemble rear bearing cap (31)		AR28.40-P-1030A
8	Remove side housing cover (71)		*BA28.40-P-1006-01A
9	Remove gearshift lever and shift tower		AR28.60-P-1007A
10	Disassemble shift tower		AR28.60-P-1006A
11	Remove needle roller bearing (12) and synchronizer
12	Remove pilot bushings with spring and slider for four-wheel drive and reduction group
13	Remove shift detent		AR28.60-P-1006-06A
14	Remove shift fork (68)		AR28.60-P-1006-03A
15	Remove bearing bracket (67)		AR28.60-P-1006-08A
16	Disassemble drive shaft (37)		AR28.50-P-1017A
17	Remove oil baffle plate (26)
18	Remove ball bearing (34)		AR28.50-P-1017-10A
		 Drift	*389589021500
		 Drift	*460589001400
		 Drift	*460589101500
	Assemble
19	Install ball bearing (34)		AR28.50-P-1017-11A
		 Drift	*389589021500
		 Drift	*460589001400
20	Install oil baffle plate (26)
			*BA28.40-P-1007-01A
21	Assemble (37) drive shaft		AR28.50-P-1017A
22	Install bearing bracket (67)		AR28.60-P-1006-05A
			*BA28.40-P-1009-01A
23	Install shift fork (68)		AR28.60-P-1006-04A
24	Check axial play of output gear (15) and input gear (10)		AR28.50-P-1030-01A
			*BE28.50-P-1001-01A
			*BE28.50-P-1002-01A
25	Install shift detent		AR28.60-P-1006-07A
26	Determine shim thickness		AR28.50-P-1031-01A
27	Install pilot bushings with spring and slider for four-wheel drive and reduction group
28	Install needle roller bearing (12) and synchronizer
29	Assemble shift tower	 Assembly: Insert the shift rod of the shift tower into the bearing bracket in such a way that the thread for the shift detent is on the opposite side to the stop lug	AR28.60-P-1006A
30	Install gearshift lever and shift tower	 Coat separating surface of shift tower with sealant	AR28.60-P-1007A
31	Install side housing cover (71)	 Coat contact face with sealant
			*BA28.40-P-1006-01A
			*BR00.45-Z-1006-01A
32	Assemble rear bearing cap (31)		AR28.40-P-1030A
		 Check tapered roller bearing, if necessary
		replace tapered roller bearing	AR28.50-P-1031-06A
33	Install rear bearing cap (31)		AR28.40-P-1500A
34	Install speedometer drive		AR28.40-P-1001A
35	Install radial shaft sealing ring (3, 4, 20, 21) on output flange to front axle	 The two radial shaft sealing rings have the same dimensions; they are just made from different materials	AR28.10-P-4075A
36	Install radial shaft sealing ring (63, 64) at output flange to rear axle	 The two radial shaft sealing rings have the same dimensions; they are just made from different materials	AR28.10-P-4150A
37	Check transfer case for proper operation

Test values for transfer case gear set, shafts

Number	Designation		Model 460, 461 with transfer case 750.60


BE28.50-P-1001-01A	Axial play of drive wheels on output shaft	mm	0,07 (0,03)
BE28.50-P-1002-01A	Axial play of drive wheel on input shaft	mm	0,25 (0,15)

 Transfer case housing

Number	Designation		Model 460, 461 with transfer case 750.60


BA28.40-P-1003-01A	Nut on output flange to front and rear axle	Nm	200
BA28.40-P-1006-01A	Bolt, side housing cover and shift tower to transmission housing	Nm	25
BA28.40-P-1007-01A	Bolt, oil baffle plate to housing	Nm	25
BA28.40-P-1009-01A	Bolt, shift fork bearing bracket to housing	Nm	25
BA28.40-P-1011-01A	Bolt, sealing flange to rear bearing cap	Nm	10