Remove/install transfer case · ar2810d0100c · Mercedes-Benz WIS

AR28.10-D-0100C

Remove/install transfer case

17.10.11

MODEL 903.0 /4, 904.0 /4 with CODE (ZG3) Engageable all-wheel drive with gear reduction

D28.10-0023-06

1 Transfer case

2 Rear axle propeller shaft

3 Front axle transmission propeller shaft

4 Vacuum line

5 Seal

6 Vent line

7 Banjo bolt

8 Clutch

9 Screw

10 Nut

11 Nut

12 Transmission propeller shaft

13 Vacuum line

14 Clutch

15 Speedometer pulse generator

16 Screw

17 Shim plate

18 Screw

Modification notes

10.8.00

Value changed from 10 Nm to 15 Nm

Value in BA28.10-N-1002-01C on model 903.0/4, 904.0/4 with code ZG2/ZG3 changed

 	Remove/install
 Installation	Replace self-locking nuts
1	Disconnect front axle differential propeller shaft (3) from transfer case (1) at flange		*BA41.10-N-1005-01B
2	Disconnect transmission propeller shaft (12) from transfer case (1) at the flange		*BA41.10-N-1007-01B
3	Disconnect rear axle propeller shaft (2) from transfer case (1) at flange	  Tie up propeller shaft (2), e.g. using welding wire	*BA41.10-N-1006-01B
4	Pull off vacuum lines (4, 13).	 Mark before removal
5	Unscrew connectors (8, 14)	 Mark before removal
6	Unscrew vent line (6)	  Installation: Replace seals (5)	*BA28.10-N-1002-01C
7	Remove speedometer pulse generator (15)		*BA28.19-N-1004-01B
8	Remove crossbar with transfer case, after this unbolt crossbar from transfer case	 Support transfer case and secure to prevent it from falling down	AR28.10-D-0300-01A
		 Installation: Screw traverse onto transfer case first, then install together in the vehicle	AR28.10-D-0300-02A
			*BA28.10-N-1003-01C
			*BA28.10-N-1004-01C
			*BA28.10-N-1005-01C
		Telescopic lifter gotis://H_00.10_01.0
		Transmission plate for passenger cars and commercial vehicles gotis://A_25/35/49_02.0
9	Install in the reverse order

 Transfer case complete

Number	Designation			Model 903.0/4, 904.0/4 with code ZG2/ZG3


BA28.10-N-1002-01C	Banjo bolt, vent lines to transfer case	M101	Nm	15
BA28.10-N-1003-01C	Nut, crossbar to transmission bracket	M8	Nm	25
BA28.10-N-1004-01C	Bolt, crossbar to frame	M121.5	Nm	90
BA28.10-N-1005-01C	Nut, crossmember to transfer case	M10	Nm	45

Transfer case electrical system

Number	Designation		Models 903.0/4/6, 904.0/4/6 with code ZG2/ZG3


BA28.19-N-1004-01B	Bolt, speedometer pulse generator to housing	Nm	8

 Propeller shaft

Number	Designation					Models 903.0/4, 904.0/4 with Code ZG1/ZG2/ZG3


BA41.10-N-1005-01B	Nut/bolt, propeller shaft to front axle/transfer case	M8			Nm	-
		M81			Nm	40
		M101			Nm	70
BA41.10-N-1006-01B	Nut/bolt, propeller shaft to rear axle/transfer case	M101		Stage 1	Nm	70
				Stage 2	°	-
			Screw headE14	Stage 1	Nm	-
				Stage 2	°	-
BA41.10-N-1007-01B	Bolt, propeller shaft to transmission/transfer case	M8		8.8	Nm	25
		M8		10.9	Nm	32
		M101			Nm	-