Seal transmission housing

AR28.40-P-2000QA

Seal transmission housing

06.03.2020

Model

164, 166 (except 166.006), 251.020/022/065/072/075/077/122/165/172/175/177, 292

1

Transfer case

3

Front housing half

4

Rear housing half

2

Bolts

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A



Remove

1

Drain oil from transfer case (1)

2

Remove transfer case (1) from vehicle

Model 251.020/022/065/072/075/077/122/165/172/175/177

AR28.10-P-0100RT

Model 164

AR28.10-P-0100GZ

Model 166 (except 166.006/058), 292

AR28.10-P-0100GQ



Disassemble

3

Mount transfer case (1) with mounting plate and adaptation onto assembly stand

 If the bore holes for the adaptation do not have a thread, then a thread will have to be cut before assembly.

 Adaptation

*164589004000

 Mounting plate

*164589006300

 Assembly stand

*116589065900

4

Rotate assembly stand with transfer case (1) through 180°

5

Remove bolts (2) from transfer case (1)

 Do not yet unfasten two opposing bolts (2).

6

Blow out threaded holes of the bolts (2) using compressed air gun

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

7

Rotate assembly stand with transfer case (1) back through 180°

8

Remove remaining bolts (2) from transfer case (1)

9

Blow out remaining threaded holes using compressed air gun

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

10

Pry front housing half (3) off the rear housing half (4) (arrows)


The sealing surfaces must not be damaged.
Otherwise leaks may occur.



Clean

11

Clean sealing surfaces on front housing half (3) and rear housing half (4)

Assembly cleaner

*BR00.45-Z-1028-04A

Seal

12

Apply sealing compound to sealing surface of rear housing half (4)

Notes on sealing the transmission housing

AH28.40-P-1000-01QA

Sealant, Hylomar universal sealant 80 ml

*BR00.45-Z-1010-01A



Assemble

13

Fit front housing half (3) onto rear housing half (4)

 When mounting the rear axle output flange must be rotated slightly to and fro.

14

Tighten bolts (2) in a crosswise pattern

Topical note

Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

 Model 164.1/8
Model 166 (except 166.006), 292Screw/bolt, transmission cover to transmission housing

*BA28.10-P-1005-01A

 Model 251.020/022/065/072/075/077/122/165/172/175/177Bolt, vibration damper to transfer case

*BA28.10-P-1005-01D

15

Remove transfer case (1) from assembly stand with mounting plate and adaptation



Install

16

Install transfer case (1)

Model 251.020/022/065/072/075/077/122/165/172/175/177

AR28.10-P-0100RT

Model 164

AR28.10-P-0100GZ

Model 166 (except 166.006/058), 292

AR28.10-P-0100GQ

17

Pour oil into transfer case (1) and correct oil level

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

 Model 164, 166 (except 166.006)
Double-speed
Model 164, 166 (except 166.006)
Single-speed
Model 292Transmission oil

*BF28.10-P-1001-01E

 Model 251.020/022/065/072/075/077/122/165/172/175/177Transfer case oil

*BF28.10-P-1001-01F

 Model 164.1/8
Model 166 (except 166.006)
Model 292Drain screw to transfer case

*BA28.10-P-1009-01A

 Model 164.1/8
Model 166 (except 166.006), 292Filling screw to transfer case

*BA28.10-P-1001-01A

 Model 251.020/022/065/072/075/077/122/165/172/175/177Oil drain screw to transfer case

*BA28.10-P-1004-01D

 Model 251.020/022/065/072/075/077/122/165/172/175/177Screw plug to transfer case

*BA28.10-P-1001-01D



Check

18

Check transfer case (1) for leaks

 Complete transfer case

Number

Designation

Model 164.1/8

Model 166 with transmission 722, 724
Model 292 with transmission 722

BA28.10-P-1001-01A

Filling screw to transfer case

Nm

25

25

 Complete transfer case

Number

Designation

Model 166, 292 with transmission 725.0

BA28.10-P-1001-01A

Filling screw to transfer case

Nm

25

 Complete transfer case

Number

Designation

Model 251

BA28.10-P-1001-01D

Screw plug to transfer case

Nm

25

 Complete transfer case

Number

Designation

Model 251

BA28.10-P-1004-01D

Oil drain screw to transfer case

Nm

25

 Complete transfer case

Number

Designation

Model 164.1/8

Model 166 with transmission 722, 724
Model 292 with transmission 722

BA28.10-P-1005-01A

Screw/bolt, transmission cover to transmission housing

Nm

34

32

 Complete transfer case

Number

Designation

Model 166, 292 with transmission 725.0

BA28.10-P-1005-01A

Screw/bolt, transmission cover to transmission housing

Nm

32

 Complete transfer case

Number

Designation

Model 251

BA28.10-P-1005-01D

Bolt, vibration damper to transfer case

Nm

35

 Complete transfer case

Number

Designation

Model 164.1/8

Model 166 with transmission 722, 724
Model 292 with transmission 722

BA28.10-P-1009-01A

Drain screw to transfer case

Nm

25

25

 Complete transfer case

Number

Designation

Model 166, 292 with transmission 725.0

BA28.10-P-1009-01A

Drain screw to transfer case

Nm

25

 Complete transfer case

Number

Designation

Model 164, 166
except code 430 (Offroad package)

Model 164, 166
with code 430 (Offroad package)

BF28.10-P-1001-01E

Transmission oil

Filling capacity

Liter

0,5

1,5

Sheet

BB00.40-P-0236-12A

BB00.40-P-0236-12A

 Complete transfer case

Number

Designation

Model 292

BF28.10-P-1001-01E

Transmission oil

Filling capacity

Liter

0,5

Sheet

BB00.40-P-0236-12A

 Complete transfer case

Number

Designation

Model 251

BF28.10-P-1001-01F

Transfer case oil

Filling capacity

Liter

0,5

Sheet

BB00.40-P-0236-12A

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-01A

Sealant, Hylomar universal sealant 80 ml

A 001 989 25 20

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01