Assemble transfer case

AR28.10-W-1002HD

Assemble transfer case

21.07.2017

Transfer case

750.855 in model 964

with code G4E (Transfer case VG 3000-3W, 1.04, engageable)

1

Coupling flange

13

Drive shaft

25

Tapered roller bearing

2

Shift housing

14

Countershaft

26

Tapered roller bearing

3

Shift cylinder

15

Output shaft

27

Bearing outer race

4

Coupling flange

16

Oil deflector

28

Bearing outer race

5

Piston rod

17

Housing cover

29

Tapered roller bearing

6

Shift fork

18

Screw

30

Tapered roller bearing

7

Sliding sleeve

19

Coupling flange

31

Bearing outer race

8

Ball

20

Bearing outer race

32

Shim

9

Drive shaft

21

Tapered roller bearing

33

Shim

10

Shift unit

22

Tapered roller bearing

34

Shim

11

Screw

23

Bearing outer race

35

Retaining ring

12

Housing

24

Bearing outer race

B80

Transfer case temperature sensor

15

Output shaft

36

Brass bush

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Assemble

1

Coat brass bushing (36) with lubricant and install in output shaft (15)

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

2

Install snap ring (35) in output shaft (15)

3

Heat tapered roller bearings (29, 30) to 80 °C and mount at output shaft (15) with zero clearance

4

Heat tapered roller bearings (25, 26) to 80 °C and mount at countershaft (14) with zero clearance

5

Heat tapered roller bearings (21, 22) to 80 °C and mount at drive shaft (13) with zero clearance

6

Determine shim (34) of output shaft (15)

AR28.50-W-1015-01HD

 Preload of bearings in clamping device

*BA28.50-N-1004-01H

Axial play for output shaft to rear axle

*BE28.50-N-1004-01H

 Tensioning device

*750589043100

 Adapter/plates

*750589053100

 Residual stroke gauge

*714589052100

7

Determine shim (33) of countershaft (14)

AR28.50-W-1018-03HC

 Preload of bearings in clamping device

*BA28.50-N-1004-01H

Countershaft axial play

*BE28.50-N-1002-01H

 Adapter/plates

*750589053100

 Tensioning device

*750589043100

8

Determine shim (32) for drive shaft (13)

AR28.50-W-1017-07HC

 Preload of bearings in clamping device

*BA28.50-N-1004-01H

Input shaft axial play

*BE28.50-N-1001-01H

 Tensioning device

*750589043100

 Adapter/plates

*750589053100

9

Install determined shim (34) for output shaft (15) and bearing outer race (28) in housing (12)

 Use a suitable drift.

10

Install determined shim (33) for countershaft (14) and bearing outer race (24) in housing (12)

 Use a suitable drift.

11

Install determined shim (32) for drive shaft (13) and bearing outer race (20) in housing (12)

 Use a suitable drift.

12

Install bearing outer races (23, 27, 31) in housing cover (17)

 Use a suitable drift.

13

Install output shaft (15) in housing cover (17)

 Retaining device

*715589053100

 Adapter

*715589223400

 Gripper

*750589093400

14

Install countershaft (14) in housing cover (17)

 Adapter set

*715589226300

15

Install drive shaft (13) in housing cover (17)

 Adapter set

*715589226300

16

Install oil deflector (16)

17

Clean sealing surface and coat with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

18

Screw in drifts into housing cover (17)

 Use drift 03.

 Drift

*715589091500

19

Mount housing (12) at housing cover (17) and fasten

 Housing cover on housing

*BA28.40-N-1002-01H

20

Position transfer case vertical

 Adapter set

*715589226300

21

Install radial shaft sealing rings of coupling flanges (4, 19)

AR28.40-W-0002HC

22

Install connector flanges (4, 19)

AR28.50-W-0001HC

23

Install shift housing (2)

AR28.40-W-1007HD

24

Install transfer case temperature sensor (B80)

 Temperature sensor to transfer case

*BA28.19-N-1001-01H

25

Pour transmission oil into transfer case



AP28.00-W-2801H

26

Install transfer case.

AR28.10-W-0100HC

Gear set, shafts

Number

Designation

Transfer case 750.855

BE28.50-N-1001-01H

Input shaft axial play

mm

-0,05...+0,10

Gear set, shafts

Number

Designation

Transfer case 750.855

BE28.50-N-1002-01H

Countershaft axial play

mm

-0,05...+0,10

Gear set, shafts

Number

Designation

Transfer case 750.855

BE28.50-N-1004-01H

Axial play for output shaft to rear axle

mm

-0,05...+0,10

 Transfer case electrical system

Number

Designation

Transfer case 750.855

BA28.19-N-1001-01H

Temperature sensor to transfer case

Nm

60

 Transfer case housing

Number

Designation

Transfer case 750.855

BA28.40-N-1002-01H

Housing cover on housing

Nm

110

 Transfer case gear set, shafts

Number

Designation

Transfer case 750.855

BA28.50-N-1004-01H

Preload of bearings in clamping device

Nm

10

Repair materials

Number

Designation

Order number

BR00.45-Z-1008-06A

Grease, silicone-based, 100 g

A 001 989 28 51

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10