Remove/installing radial shaft seal at output flange to front axle

AR28.10-P-4075RT

Remove/installing radial shaft seal at output flange to front axle

17.6.11

11.1.07

Document for new repair method revised



Removing

 Danger!

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities

No parts of the body or limbs should be within the operating range of the mechanism when moving components.

AS00.00-Z-0009-01A

1

Drain oil from transfer case (1)

2

Remove transfer case (1) from vehicle.

AR28.10-P-0100GZ



Disassemble

3

Assemble the transfer case (1) with support plate (020) and adaptation (030) on the assembly stand (010)

 If there are no threads in the bores (2), threads must be incorporated before assembly.



*116589065900



*164589006300



*164589004000

4

Turn assembly stand (010) with transfer case (1) through 180° and unscrew bolts (3)

 Do not loosen two opposite bolts (3) yet.

5

Blow out threaded holes of the bolts (3) with compressed air gun

 Blowing out is necessary so that no shavings from the threaded holes get into the transfer case (1).

6

Turn back assembly stand (010) with transfer case (1) by 180°, unscrew remaining bolts (3) and blow out threaded holes

7

Separate front housing half (4) from rear housing half (5) and take off

8

Mount front housing half (4) on workshop press

9

Pretension output flange of front axle (6) slightly using workshop press

10

Compress circlip (7) using a suitable tool (arrows) and press output flange of front axle (6) out of front housing half (4)

 Protect output flange of front axle (6) to prevent it from falling down otherwise damage can occur.

 Increase pressure of the workshop press until the output flange of front axle (6) detaches downwards out of the bearing.

11

Remove radial shaft sealing ring from outside

 Carefully pry out radial shaft sealing ring using a suitable tool so that the seat of the radial shaft sealing ring is not damaged.



Assemble

12

Assemble radial shaft sealing ring with drift



*164589001500

13

Press output flange of front axle (6) into the front housing half (4)

 Check output flange of front axle (6) for wear and damage.

The circlip (7) must be replaced.

 Pay attention to correct seat of circlip (7). The circlip (7) must engage audibly.



Clean

14

Clean the sealing surfaces on the front and rear housing half (4, 5)

*BR00.45-Z-1028-04A

15

Coat sealing compound on sealing surface of rear housing half (5)

*BR00.45-Z-1010-01A

16

Fit front housing half (4) on rear housing half (5)

 When mounting, the output flange of the rear axle (12) must be turned to and fro.

17

Tighten bolts (3) in a crosswise pattern



*BA28.10-P-1005-01A



Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

18

Detach transfer case (1) from assembly stand (010) with support plate (020) and adaptation (030)



Install

19

Install transfer case (1)

AR28.10-P-0100GZ



Checking

20

Pour oil into transfer case (1) and check oil level and correct if necessary

 The transfer case (1) is filled correctly when the oil level reaches to the bottom edge of the oil filler screw (screw plug).



*BA28.10-P-1001-01A



*BA28.10-P-1009-01A



*BF28.10-P-1001-01E

21

Check transfer case (1) for leaks

Number

Designation

Model
164.1/8

BA28.10-P-1001-01A

Screw plug to transfer case

Nm

25

BA28.10-P-1005-01A

Bolt, transmission cover to transmission housing

Nm

34

BA28.10-P-1009-01A

Oil drain screw to transfer case

Nm

25

Number

Designation

Model
164, 166
Double-Speed

BF28.10-P-1001-01E

Gear oil

Filling capacity

Liters

1.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0236-12A

Number

Designation

Order number

BR00.45-Z-1010-01A

Hylomar universal sealant 80 ml

A 001 989 25 20

BR00.45-Z-1028-04A

Cleaner from package

Adolf Würth GmbH & Co. KG
Reinhold-Würth-Str. 12-17
74653 Künzelsau-Gaisbach
Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de