Remove/install rear cover on transfer case

AR28.40-S-0815E

Remove/install rear cover on transfer case

06.03.2020

Model

447 with transmission 725.0

with code ZG2 (Permanent all-wheel drive)

1

Cover

8

Screw

11

Screw

6

Intermediate housing

9

Screw

12

Screw

7

Screw

10

Screw

13

Screw

2

Oil nozzle

6

Intermediate housing

6

Intermediate housing

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

Topical note

General information on repair work on transmission

AH27.00-S-1000-01PS



Remove

1

Drain transmission oil from transfer case.



AP28.00-S-2801E

2

Remove propeller shaft.

AR41.10-S-0050E

3

Remove screws (7 to 13).

4

Detach cover (1) from intermediate housing (6).



Check

5

Check oil nozzle (2) in intermediate housing (6) for damage.

If the oil nozzle (2) is damaged,



replace oil nozzle (2).

 Make sure that the oil nozzle (2) engages correctly in the intermediate housing (6).



Clean

6

Clean sealing surfaces and check for damage.

Assembly cleaner

*BR00.45-Z-1028-04A

If damage is found,



replace transfer case.



Install

7

Apply sealant to sealing surface of intermediate housing (6).


The sealing surfaces must be free of oil, grease and dirt.
Leaks may occur otherwise.

 The sealant seam must not be broken. The sealant must be applied uniformly and continuously on the intermediate housing (6) without any bubbles. The starting and ending point for sealant application must overlap. The sealant seam must have a width of at least 2 mm.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

8

Position cover (1) on intermediate housing (6) and press on.

9

Tighten screws (7 to 13) slightly by hand and tighten completely in numerical sequence.

 Bolt, rear transfer case cover to transfer case

*BA28.10-N-1004-01EB

10

Install propeller shaft.

AR41.10-S-0050E

 Only install underfloor paneling after the leak test.

11

Fill transfer case with transmission oil.



AP28.00-S-2801E

 Only install the engine compartment lining after the leak test.

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

12

Perform engine test run and check transfer case for leak tightness and proper operation.

 Complete transfer case

Number

Designation

Model 447 with transmission 725.0
with code ZG2 (Permanent all-wheel drive)

BA28.10-N-1004-01EB

Bolt, rear transfer case cover to transfer case

Nm

32

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01