W28.10-1099-09
1 | Shift housing | 17 | Spring | 32 | Oil retaining element | ||
2 | On-road and off-road gear shift cylinder | 18 | Tapered roller bearing | 33 | Seal | ||
3 | Seal | 19 | Drive shaft | 34 | Bearing outer race | ||
4 | Coupling flange | 20 | Housing | 35 | Tapered roller bearing | ||
5 | Radial shaft sealing ring | 21 | Temperature sensor | 36 | Ring gear | ||
6 | Drive shaft housing cover | 22 | Bearing outer race | 37 | Bearing outer race | ||
7 | Seal | 23 | Seal | 38 | Tapered roller bearing | ||
8 | Shim | 24 | Cover | 39 | Shim | ||
9 | Bearing outer race | 25 | Seal | 40 | Planetary gear set | ||
10 | Guide ring | 26 | Shift cylinder | 41 | Tapered roller bearing | ||
11 | Sealing ring | 27 | Coupling flange | 42 | Tapered roller bearing | ||
12 | Shift piston | 28 | Radial shaft sealing ring | 43 | Countershaft | ||
13 | Magnet | 29 | Tapered roller bearing | 44 | Housing cover | ||
14 | Shift rod | 30 | Bearing outer race | 45 | Bearing outer race | ||
15 | Shift fork | 31 | Oil retaining element | 46 | Seal | ||
16 | Shim |
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. | |
| Assemble | ||
1 | Assemble and install ring gear (36) | ||
Tensioning device | |||
2 | Heat coupling flange (27) to rear axle to approx. 80 °C and install | Coupling flange to rear axle | |
Ratio wrench | |||
Retainer wrench | |||
3 | Check end play of ring gear (36) | ||
Axial play in hollow gear | |||
Dial indicator holder | |||
Dial gage | |||
4 | Remove coupling flange (27) | Use corresponding thrust piece. | |
Retainer wrench | |||
Puller | |||
5 | Fill space between sealing lips on new radial shaft sealing ring (28) with lubricant | Long-life grease | |
6 | Install radial shaft sealing ring (28) in rear transmission housing (20) | Drift | |
7 | Heat coupling flange (27) to approx. 80 °C and install | Coupling flange to rear axle | |
Ratio wrench | |||
Retainer wrench | |||
8 | Assemble planetary gear set (40) | ||
9 | Assemble countershaft (43) | ||
10 | Assemble drive shaft (19) | ||
11 | Assemble shift housing (X) | ||
12 | Install outer races of tapered roller bearing (22) in rear transmission housing (20) | ||
13 | Attach cap (24) with screws M10 and new seal (23) to rear transmission housing (20) | Screw in screws M10 by only 2 threads. So that the tapered roller bearing outer races (22) still have play. | |
14 | Install countershaft (44), planetary gear set (45) and drive shaft (36) | ||
15 | Install oil retaining elements (31, 32) | ||
Oil retaining element to housing | |||
16 | Install front transmission housing (44) with new seal (33) | Only tighten 2 opposing screws. | |
Housing cover on housing | |||
17 | Check/adjust installation height of planetary gear set (45) | ||
18 | Install tapered roller bearing outer races (9, 45) into front transmission housing (44) | ||
19 | Attach new guide ring (10) to shift rod (38) and grease sealing ring (11) | Synthetic grease 50 g | |
20 | Install on-road and off-road gear shift cylinder (18) | ||
21 | Position transfer case vertical | ||
22 | Install screws around circumference of transfer case and tighten | CHECK: 3 different screws M 14 and M 10, rear cover to rear housing / M12 rear housing to front housing | |
Housing cover on housing | |||
23 | Install neutral position shift cylinder (26) with new seal (25) | Shift cylinder, neutral to transfer case | |
24 | Determine size of shim (8) for drive shaft (19) | ||
End play for drive shaft to front axle | |||
Protrusion involute profile from planetary gear system to housing | |||
Strip clamp | |||
Torque wrench | |||
25 | Install determined shim (8) in drive shaft housing cover (6) | ||
26 | Install radial shaft sealing ring (5) in drive shaft housing cover (6) | Drift | |
27 | Attach drive shaft housing cover (6) with sealant to front transmission housing (44) | Loctite 5203 sealant | |
Housing cover, drive shaft to housing | |||
28 | Heat coupling flange (4) to approx. 80 °C and install | Drive shaft coupling flange | |
Ratio wrench | |||
Retainer wrench | |||
29 | Attach shift housing (1) with new seal to transfer case | ||
30 | Install temperature sensor (21) | ||
31 | Install transfer case. | Removal instructions have not yet been prepared for this transfer case. |
001 589 53 21 00
Dial gage
000 589 67 21 00
Torque wrench
000 589 69 63 00
Ratio wrench
000 589 59 63 00
Strip clamp
620 589 02 63 00
Tensioning device
000 589 89 33 00
Puller
363 589 02 21 00
Dial indicator holder
717 589 00 31 00
Retainer wrench
620 589 02 15 00
Drift
Referenced documents
- ar2810w100002he Check axial play of ring gear
- ar2810w100007he Remove/install oil retaining element
- ar2810w100008he Install drive shaft, planetary gear set and countershaft
- ar2810w100013he Assemble and install ring gear
- ar2840w1007he Remove/install shift housing on transfer case
- ar2850w1003he Disassemble, assemble planetary gear system
- ar2850w101717he Determine shim for drive shaft
- ar2850w1017he Dismantle, assemble drive shaft.
- ar2850w1018he Disassemble, assemble countershaft
- ar2860w0002he Remove/install on-road and off-road gear shift cylinder
- as0000z000201a Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.