Assemble transfer case

AR28.10-D-1002B

Assemble transfer case

16.10.09



Assemble

1

Install bushings (49)

As of transfer case End no.: 000820

AR28.10-D-1002-02A

Sealant

*BR00.45-Z-1026-01A

2

Install circlip (4).

Retaining ring pliers

Check that retaining ring is correctly seated.

3

Install tapered roller bearing outer races (25, 30, 36)

 Drive the tapered roller bearing outer races all the way into the housing from inside.

*389589011500

4

Install tapered roller bearing outer races (29, 34, 45)

 Drive in the outer races from inside so that they are flush with the housing.

*460589151500

5

Place tapered roller bearings (26, 28) on intermediate shaft (27)

 Heat up the tapered roller bearing to

125 °C.

  Position using a drift if necessary.

*460589151500

6

Place tapered roller bearing (31, 33) on intermediate shaft (32)

 Heat up the tapered roller bearing to

125 °C.

  Position using a drift if necessary.

*460589151500

7

Assemble front axle output shaft (42)

AR28.50-D-1000-04A



*BA28.50-N-1001-01B

 Drift

*460589151500

 Heat up the tapered roller bearing to

125 °C.

8

Secure collar nut (35)

AR33.30-D-0085-03A

9

Clean sealing surfaces of housing parts (8, 9)

10

Prepare shift fork (47) for installation

AR28.50-D-1002-02A

Sealant

*BR00.45-Z-1026-01A

Lubricant

*BR00.45-Z-1001-06A

11

Insert front axle output shaft (42) with shift fork (47) in the housing rear part (8)

 Make sure that the shift fork is fitted at the correct position.

12

Insert drive shaft (27) and intermediate shaft (32)

13

Attach housing front section (9)

 The bearing play is adjusted by the retaining ring thickness

AR28.10-D-1002-01A



*BA28.40-N-1003-01E

Retaining ring pliers



Circlip set for determining circlip thickness

WF58.50-N-2810-01A

14

Install cap (20)

 Replace the cap.

15

Tighten pressure switch (10)

 Fit new sealing ring

*BA28.19-N-1003-01B

16

Install radial shaft sealing rings (3, 14, 22)

  Replace the radial shaft sealing rings.

*750589021500

17

Install coupling flanges (2, 15, 23)

  Replace the collar nuts.

*BA28.10-N-1006-01C



*BA28.10-N-1007-01C

 Retainer wrench

*717589003100

18

Secure collar nuts (1, 16, 24)

AR33.30-D-0085-03A



Install

19

Install transfer case.

AR28.10-D-0100A

20

Pour oil into transfer case

AP28.00-D-2801A

Number

Designation

Model 903.0/4, 904.0/4
with code ZG1/ZG3

BA28.50-N-1001-01B

Nut to front axle output shaft

Nm

200

Number

Designation

Models 903.0/4/6, 904.0/4/6
with code ZG1

BA28.40-N-1003-01E

Nut securing front housing section to rear housing section

Nm

28

Number

Designation

Models 903.0/4/6, 904.0/4/6 with code ZG1

BA28.19-N-1003-01B

Temperature sensor to housing

Nm

9

Number

Designation

Models 903.0/4, 904.0/4
with code ZG1

BA28.10-N-1006-01C

Nut, coupling flange to transmission/to front axle to transfer case

M261.5

Nm

300

BA28.10-N-1007-01C

Nut, coupling flange to rear axle to transfer case

M261.5

Nm

300

Number

Designation

Order number

BR00.45-Z-1026-01A

Terostat 33 sealant

A 001 989 61 20

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11