Remove/install output shaft relative to the front axle

AR28.50-W-1004R

Remove/install output shaft relative to the front axle

24.11.08



Remove

1

Disassemble transfer case

AR28.10-W-1001R

2

Remove coupling flange to front axle

AR28.40-W-0001R

3

Remove output shaft (6)

 Remove the output shaft (6) using a soft metal drift or using a hydraulic press.

The output shaft (6) must not jam in the sliding sleeve (5).

4

Pull out shift rod (4)

5

Remove sliding sleeve (5), shift fork (3) and compression spring (2)

6

Remove circlip (7)

7

Remove ball bearing (8) and shim (9)

 Use a suitable drift.

8

Remove radial sealing rings (10, 11) from output shaft (6)



Install

9

Insert shims (9) and install ball bearings (8)

 Use a suitable drift.

10

Install circlip (7).

11

Check axial play of ball bearing (8) using feeler gauge, correct if necessary

AR28.50-W-1004-01B

*BE28.50-N-1005-01A

 Countersupport

*000589353300

 Internal extractor

*000589683300

12

Insert compression spring (2) into housing front section (1)

13

Insert sliding sleeve (5) into shift fork (3) and fit shift fork (3) above compression spring (2)

 The rounded teeth on the sliding sleeve (5) should be toward the output end.

14

Install shift rod (4)

 Align the shift fork (3) and compression spring (2) with the housing and insert the shift rod (4) with the short end.

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

15

Heat up ball bearing (8) to max. 80 °C and install output shaft (6)

When doing so, guide the output shaft (6) through the sliding sleeve (5).

16

Install radial sealing rings (10, 11) and coupling flange to front axle

AR28.40-W-0001R

17

Assemble transfer case

AR28.10-W-1002R

Number

Designation

Transfer case 750.860/861/
864/865

BE28.50-N-1005-01A

Axial play of ball bearings on output shaft to front axle

mm

0...0.1