Remove/install transfer case

AR28.10-P-0100RT

Remove/install transfer case

26.03.2018

Model

251.020/022/065/072/075/077/122/157/165/172/175/177

Shown on MODEL 251 with ENGINE 113

1

Underfloor paneling, left

2

Bolts of exterior reinforcement brace

3

Inner reinforcement brace bolts

4

Reinforcement brace

Shown on MODEL 251 with ENGINE 113

5

Center support bolts

6

Center support

7

Bolted connections

8

Hose clamp screw

9

Exhaust suspension bolts

10

Exhaust rubber mount

Shown on MODEL 251 with ENGINE 113

11

Support brace

14

Engine suspension

12

Bolts of rear engine mount

15

Rear engine mount

13

Engine suspension bolts

16

Rear propeller shaft bolts

Shown on MODEL 251 with ENGINE 113

11

Support brace

21

Rear exhaust system

17

Bolts of front propeller shaft

22

Front exhaust system

18

Rear propeller shaft

23

Transfer case bolts

19

Front propeller shaft

24

Telescopic lifter

20

Transfer case

Shown on MODEL 251 with ENGINE 113

20

Transfer case

25

Transfer case primary shaft

24

Telescopic lifter

 Danger

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

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

AS00.00-Z-0010-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Remove bolts of inner reinforcement brace (3)

 Bolt, reinforcement brace to rear engine crossmember

*BA22.10-P-1006-03F

2

Remove bolts of outer reinforcement brace (2), remove reinforcement brace (4)

 Bolt, reinforcement brace to body

*BA22.10-P-1007-03F

3

Remove bolts of center support (5), remove center support (6)

 Bolt, stiffening bridge to frame floor assembly

*BA61.10-P-1005-01F

4.1

Remove right and left catalytic converter

Model 251.065/165 with engine 272
Model 251.072/172 with engine 273
Model 251.075/175 with engine 113
Model 251.077/177 with engine 156
Model 251.157 with engine 276

Model 251.075/175 with engine 113.971
Left catalytic converterModel 251.077/177 with engine 156.980Left catalytic converter

AR49.10-P-5500RTN

Model 251.075/175 with engine 113.971
Right catalytic converterModel 251.077/177 with engine 156.980Right catalytic converter

AR49.10-P-5500RTM

Model 251.065/165 with engine 272
Model 251.072/172 with engine 273
Model 251.157 with engine 276

AR49.10-P-7100GZA

4.2

Remove diesel particulate filter

Model 251.020/022/122 with engine 642

AR49.10-P-7100GZB

5

Support transfer case (20) using a suitable vertically adjustable support brace (11)

6

Remove bolts of rear engine mount (12) and remove bolts of engine mount (13) , remove engine mount (14)

Model 251.020/022/065/072/122/157/165/172 with engine 272, 273, 276, 642

AR22.10-P-1180GZD

Model 251.075/175 with engine 113.971

AR22.10-P-1170RT

Model 251.077/177 with engine 156

AR22.10-P-1170GZS

7

Remove support brace (11) from transfer case (20) and place on rear engine mount (15)

 Do not allow the drive train to hang freely when repositioning the support brace (11).

 Make sure that the support (11) will not impede the telescopic lifter (24) when it is used later on. If necessary, the support (11) can also be positioned between the rear engine mount (15) and the oil pan.

8

Mark rear propeller shaft (18) and front propeller shaft (19) relative to output flanges of transfer case (20)

 Installation: Align the rear drive shaft (18) and the front drive shaft (19) with the markings on the output flanges of the transfer case (20).

9

Detach rear propeller shaft (18) from output flange of transfer case (20)

Tightening procedure for rear propeller shaft to transfer case

AR41.10-P-0050-17GZ


Always observe the tightening procedure.
Otherwise noise development and vibrations will occur.


The rear drive shaft (18) must be secured against buckling.
Otherwise, the drive shaft will be damaged.

 Self-locking bolt, propellor shaft to transfer case (to rear axle)

*BA41.10-P-1001-01G

 Retainer wrench

*164589020700

10

Detach front propeller shaft (19) from output flange of transfer case (20)

Tightening procedure for front propeller shaft

AR41.10-P-0070-03GZ


The front drive shaft (19) must be secured against buckling.
Otherwise, the drive shaft will be damaged.


Always observe the tightening procedure.
Otherwise noise development and vibrations will occur.

 Self-locking bolt, propellor shaft to transfer case (to front axle)

*BA41.10-P-1003-01G

 Retainer wrench

*164589020700

11

Lower the transfer case (20) as far as possible

 Pull rear exhaust system (21) to the rear while draining the transfer case (20).

 Secure rear exhaust system (21) onto vehicle floor.

 Get help if necessary.

 The support brace (11) must not be relieved of load completely.

12

Remove the top four and bottom two bolts of the transfer case (23)

 Bolt, transfer case to automatic transmission

*BA28.10-P-1002-01D

13

Secure transfer case (20) on telescopic lifter (24)

14

Remove the remaining two bolts of the transfer case (23)

 Bolt, transfer case to automatic transmission

*BA28.10-P-1002-01D

15

Push transfer case (20) towards rear (arrow A), lower (arrow B) and remove

 Installation: Apply light coating of grease to primary shaft on transfer case (25).

Long-life grease

*BR00.45-Z-1001-06A

16

Install in the reverse order



Check

17

Check oil level in transfer case (20) and correct if necessary

 Screw plug to transfer case

*BA28.10-P-1001-01D

 Transfer case oil

*BF28.10-P-1001-01F

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

18

Carry out engine test run and check exhaust system and transfer case (20) for leaktightness

 Engine mount, engine support (engine side)

Number

Designation

Model 251

BA22.10-P-1006-03F

Bolt, reinforcement brace to rear engine crossmember

Nm

19

 Engine mount, engine support (engine side)

Number

Designation

Model 251

BA22.10-P-1007-03F

Bolt, reinforcement brace to body

Nm

19

 Complete transfer case

Number

Designation

Model 251

BA28.10-P-1001-01D

Screw plug to transfer case

Nm

25

 Complete transfer case

Number

Designation

Model 251

BA28.10-P-1002-01D

Bolt, transfer case to automatic transmission

Nm

45

 Propeller shaft

Number

Designation

Model 251

BA41.10-P-1001-01G

Self-locking bolt, propellor shaft to transfer case (to rear axle)

Stage 1

Nm

40

Stage 2

°

90

 Propeller shaft

Number

Designation

Model 251

BA41.10-P-1003-01G

Self-locking bolt, propellor shaft to transfer case (to front axle)

Stage 1

Nm

40

Stage 2

°

90

 Frame floor assembly

Number

Designation

Model 251

BA61.10-P-1005-01F

Bolt, stiffening bridge to frame floor assembly

Nm

20

 Complete transfer case

Number

Designation

Model 251

BF28.10-P-1001-01F

Transfer case oil

Filling capacity

Liter

0,5

Sheet

BB00.40-P-0236-12A

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11