Remove/install cap on front of transfer case

AR28.40-S-0816E

Remove/install cap on front of transfer case

06.03.2020

Model

447 with transmission 725.0

with code ZG2 (Permanent all-wheel drive)

1

Cover

7

Screw

12

Screw

2

Radial shaft sealing ring

8

Screw

13

Screw

3

Retaining ring

9

Screw

14

Screw

4

Washer

10

Screw

15

Screw

5

Roller bearing

11

Screw

3

Retaining ring

4

Washer

5

Roller bearing

6

Intermediate housing

16

Permanent magnet

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 transfer case.

AR28.10-S-0100EA

3

Remove radial shaft sealing ring (2) from output flange to front axle.

AR28.10-S-4075EA

4

Remove circlip (3).

5

Remove washer (4).

6

Mark installation position of roller bearing (5).

7

Remove roller bearing (5).

8

Remove screws (7 to 15).

9

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



Check

10

Check for correct installation position of permanent magnets (16) in intermediate housing (6), correct if necessary.



Clean

11

Clean sealing surfaces and check for damage.

Assembly cleaner

*BR00.45-Z-1028-04A

If damage is found,



replace transfer case.



Install

12

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

13

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

14

Tighten screws (7 to 15) slightly by hand and tighten completely in numerical sequence.

 Bolt, front transfer case cover to transfer case

*BA28.10-N-1003-01EB

15

Install roller bearing (5).

 Observe installation position of roller bearing (5).

16

Insert washer (4).

17

Install retaining ring (3).

 Check that the retaining ring (3) is seated correctly in the groove.

18

Install new radial shaft sealing ring (2) at output flange to front axle.

AR28.10-S-4075EA

19

Install transfer case.

AR28.10-S-0100EA

 Only install the engine compartment lining and underfloor paneling after the leak test.

20

Fill transfer case with transmission oil.



AP28.00-S-2801E

 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

21

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-1003-01EB

Bolt, front 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