Disassembling and assembling differential lock shift cylinder

AR35.40-P-9135F

Disassembling and assembling differential lock shift cylinder

04.09.2018

Model

460

Model

461 (except 461.331)

Model

463 (except 463.270/271)

up to model year 2013

1

Pressure switch

2

Shift cylinder housing

3

Gearshift lever

4

Switch spring

5

Shift shaft

6

Return spring

7

Washer

8

Retaining ring

9

Compression spring

10

Dust boot

11

Seal boot

12

Piston

13

Seal

14

Cover

15

Screw

16

Vent valve



Remove

 Caution

Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A

1

Remove shift cylinder on differential lock

AR35.40-P-9131F

 

Disassemble/assemble

2

Unscrew pressure switch (1)

 Assembly: Only tighten pressure switch (1) to 1st stage.

 Pressure switch to shift cylinder

*BA35.40-P-1005-01A

 Socket wrench bit

*620589010900

3

Detach cap (14)

 Undo bolts (15) from cover (14), spring-loaded.

 Assembly: Install new seal (13).

 Bolt, cover to shift cylinder

*BA35.40-P-1002-01A

4

Remove piston (12) and push spring (9)

 Assembly: Replace dust boot (10) and seal boot (11), observe installation position. Coat dust boot (10), seal boot (11) and piston (12) with MB silicone grease.

ABS sensor grease

*BR00.45-Z-1019-06A

5

Unscrew shift shaft (5) from shifter lever (3)

 Assembly: Apply quick-action adhesive to the thread of the shift shaft (5).

 Shift shaft to gearshift lever for cross-axle differential lock

*BA35.40-P-1003-01A

Quick-acting adhesive, Loctite 270

*BR00.45-Z-1008-02A

6

Remove gearshift lever (3) and shift shaft (5) with switch spring (4) from the shift cylinder housing (2)

7

Disassemble shift shaft (5)

 To facilitate dismantling of the separate parts screw the gearshift lever (3) onto the shift shaft (5) and clamp in vise.

 Assembly: Circlip (8) must engage in the groove. To facilitate assembly of separate parts screw the gearshift lever (3) onto the shift shaft (5) and clamp in vise.

 Clamping device

*381589003100



Clean

8

Clean all parts

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

*BR00.45-Z-1051-04A



Check

9

Check all parts for wear and damage, replace if necessary

10

Assemble in the reverse order



Install

11

Install shift cylinder for differential lock

AR35.40-P-9131F

12

Tighten pressure switch (1)

 Tighten pressure switch (1) with the 2nd stage.

 Pressure switch to shift cylinder

*BA35.40-P-1005-01A

 Differential lock shift cylinder

Number

Designation

Model 460, 461
Model 463
up to model year 2019

Model 463
as of model year 2019

BA35.40-P-1002-01A

Bolt, cover to shift cylinder

Nm

20

-

 Differential lock shift cylinder

Number

Designation

Model 460, 461
Model 463
up to model year 2019

Model 463
as of model year 2019

BA35.40-P-1003-01A

Shift shaft to gearshift lever for cross-axle differential lock

Nm

25

-

 Differential lock shift cylinder

Number

Designation

Model 460, 461
Model 463
up to model year 2019

Model 463
as of model year 2019

BA35.40-P-1005-01A

Pressure switch to shift cylinder

Stage 1

Nm

20

-

Stage 2

Nm

105

-

Repair materials

Number

Designation

Order number

BR00.45-Z-1008-02A

Quick-acting adhesive, Loctite 270

A 002 989 93 71

BR00.45-Z-1019-06A

ABS sensor grease

A 000 989 62 51 10

BR00.45-Z-1051-04A

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

Chemische Werke Kluthe GmbH
Gottlieb-Daimler-Str. 12
69115 Heidelberg
Germany
Tel. +49 6221 5301-0
Fax +49 6221 5301-176
http://kluthe.com