Align transfer case with transmission

AR28.10-D-0500A

17.10.11

MODEL 903.6, 904.6 with CODE (ZG1) Engageable all-wheel drive

MODEL 903.6, 904.6 with CODE (ZG2) Permanent all-wheel drive

MODEL 903.6, 904.6 with CODE (ZG3) Engageable all-wheel drive with gear reduction

D28.10-1108-01

1 Transmission

2 Transfer case

D28.10-1109-01

D28.10-1111-01

3 Mount

4 Collar nut

5 Transmission bracket

D28.10-1110-01

	Removing
1	Remove propeller shaft to transfer case.		AR41.10-D-0300B
	Measure
2	Position angle gauge on transmission flange (1) and calibrate to "0°"	  See device operating instructions for information about calibrating meter.	*001589882100
3	Position angle gauge on transfer case flange (2) and determine incline angle	 If the value determined is within the specified tolerance, proceed with operation step 8.	*BE28.00-N-1001-01A
			*001589882100
	Adjust
4	Unscrew bolts of upper cradle (3) at frame crossmember bracket and at all 3 rubber mounts.
5	Slide suspension (3) with transmission into the highest possible position (arrow) and tighten suspension threaded connection as well as the upper rubber mount	  If the U section (6) is installed, it may require reworking to ensure that the bracket has sufficient clearance at the top. Refinish damaged corrosion protection.	*BA28.10-N-1010-01C
		Telescopic lifter gotis://H_00.10_01.0
6	Align transfer case and tighten remaining rubber mounts.	  Check incline angle during aligning procedure.	*BA28.10-N-1005-01C
		Telescopic lifter gotis://H_00.10_01.0
7	Check incline angle and readjust if necessary.	 If the adjustment described in step 5 is insufficient, the adjustment can also be corrected using the transmission bracket (5).
			*BA28.40-N-1003-01E
	Install
8	Install propeller shaft to transfer case.		AR41.10-D-0300B
	Notes on installing propeller shaft	Model 901, 902, 903, 904, 905, 690.6	AH41.10-N-0001-01A

Test values for transfer case, general

Number	Designation		Models 903.6, 904.6 with code ZG1/ZG2/ZG3


BE28.00-N-1001-01A	Alignment of transfer case relative to transmission	°	0 (0.3)

 Transfer case complete

Number	Designation			Models 903.6, 904.6 with code ZG1	Model 903.6, 904.6 with code ZG2/ZG3


BA28.10-N-1005-01C	Nut, crossmember to transfer case	M10	Nm	58	58
BA28.10-N-1010-01C	Bolt securing suspension/crossmember to carrier and frame console	M10	Nm	61	61

 Transfer case housing

Number	Designation		Models 903.0/4/6, 904.0/4/6 with code ZG1	Models 903.0/4/6, 904.0/4/6 with code ZG2/ZG3


BA28.40-N-1003-01E	Nut securing front housing section to rear housing section	Nm	28	28

Choke angle gauge (electronic)

001 589 88 21 00