Disassemble/assemble shift housing on transfer case

AR28.40-W-1008HD

Disassemble/assemble shift housing on transfer case

13.08.2020

Transfer case

750.855 in model 964

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

1

Coupling flange

7

Compression spring

12

Sliding sleeve

2

Engageable front axle shift cylinder

8

Transfer case

13

Balls

3

Shift piston

9

Shift unit

14

Retaining ring

4

Shift housing

10

Output shaft

15

Ball bearing

5

Piston rod

11

Pressure plate

16

Radial shaft sealing rings

6

Shift fork

 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

Notes on safety-relevant components

AH00.00-Z-0019-01A



Disassemble

1

Remove shift housing (4).

AR28.40-W-1007HD

2

Detach compression spring (7).

3

Unscrew and remove locking screw.



WF58.50-W-2851-01A

4

Install output shaft (10) in clamping device.

 Clamping device

*315589023100

5

Detach coupling flange (1).

AR28.50-W-0001HC

6

Undo screws on engageable front axle shift cylinder (2).

7

Remove engageable front axle shift cylinder (2).

 To do so, apply compressed air to the compressed air connection at the engageable front axle shift cylinder (2).

8

Remove shift piston (3) and piston rod (5).

9

Detach shift housing (4) from output shaft (10).

 Puller

*715589133300

 Adapter

*750589003300

 Hand pump

*652589003321

 Hydraulic hose (complete)

*652589003323

 Hydraulic cylinder

*715589153400

 Adapter

*715589123400

 Adapter

*715589113400

10

Detach shift fork (6).

11

Remove output shaft (10) from clamping device.

12

Remove 29 balls (13) from shift unit (9).

13

Detach sliding sleeve (12) from shift unit (9).

14

Detach pressure disk (11) from output shaft (10).

15

Remove retaining ring (14) from shift housing (4).

16

Remove ball bearing (15) from shift housing (4).

 Use a suitable drift.

17

Remove radial shaft sealing rings (16) from shift housing (4).

 Removal and insertion device

*750589004300

18

Remove pilot bushing and radial shaft sealing ring of piston rod (5) from shift housing (4).



Assemble

19

Coat new radial shaft sealing ring of piston rod (5) with lubricant and install up to contact surface using drift.

 Install the new radial shaft sealing ring with the spring lock washer facing inward (oil side).

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*714589051500

20

Install pilot bushing of piston rod (5) up to contact surface using drift.

 Drift

*714589051500

21

Install ball bearing (15) in shift housing (4).

 Use a suitable drift.

22

Install retaining ring (14) in shift housing (4).

23

Heat up pressure disk (11) to approx. 80 °C and attach to output shaft (10).

 The flat side of the pressure plate (11) must point toward the coupling flange (1).

24

Install sliding sleeve (12) on shift unit (9).

25

Clamp shift unit (9) in a vise and shift sliding sleeve (12).

26

Install 29 balls (13) in sliding sleeve (12) with lubricant.

Synthetic grease 50 g

*BR00.45-Z-1027-06A

27

Install output shaft (10) in shift unit (9).

28

Install shift fork (6) in sliding sleeve (12).

 The flat side of the shift fork (6) must point toward the transfer case (8).

29

Place shift housing (4) on output shaft (10).

30

Insert shift piston (3) with piston rod (5) into shift housing (4).

31

Press shift housing (4) onto output shaft (10) up to contact surface.

 Hand pump

*652589003321

 Hydraulic hose (complete)

*652589003323

 Hydraulic cylinder

*715589153400

 Adapter

*715589123400

 Adapter

*715589113400

 Pulling device

*715589123300

32

Fix shift fork (6) in place using locking screw.



WF58.50-W-2851-01A

33

Install radial shaft sealing rings (16) in shift housing (4).

 Removal and insertion device

*750589004300

34

Heat up coupling flange (1) to approx. 80 °C and install.

 Coupling flange to front axle

*BA28.50-N-1003-01H

35

Install engageable front axle shift cylinder (2).

 Shift cylinder, engageable front axle to transfer case

*BA28.60-N-1003-01H

Klueber Polylub GLY 801 grease

*BR00.45-Z-1046-06A

36

Attach compression spring (7).

37

Install shift housing (4).

AR28.40-W-1007HD

 Transfer case gear set, shafts

Number

Designation

Transfer case 750.855

BA28.50-N-1003-01H

Coupling flange to front axle

Nm

460

 Shift mechanism transfer case

Number

Designation

Transfer case 750.855

BA28.60-N-1003-01H

Shift cylinder, engageable front axle to transfer case

Nm

60

Repair materials

Number

Designation

Order number

BR00.45-Z-1027-06A

Synthetic grease 50 g

A 001 989 32 51 10

BR00.45-Z-1046-06A

Klueber Polylub GLY 801 grease

A 001 989 84 51