Disassembling transfer case · ar2810d1001d · Mercedes-Benz WIS

AR28.10-D-1001D

Disassembling transfer case

17.12.98

MODEL 903.0 /4, 904.0 /4 with CODE (ZG2) permanent all-wheel drive

D28.10-0029-09

D28.10-0030-09

1 Collared nut

2 Coupling flange

3 Rotary shaft seal

4 Tapered roller bearing

5 Tapered roller bearing outer race

6 Roll pin

7 Bolt

8 Washer

9 Bearing cover

10 Gasket

11 Screw plug

12 Sealing ring

13 Sealing ring

14 Oil line

15 Banjo bolt

16 Sealing ring

17 Nut

18 Washer

19 Rear bracket

20 Rear section of housing

21 Front section of housing

22 Pressure switch

45 Intermediate shaft

46 Tapered roller bearing

47 Tapered roller bearing outer race

48 Bush

49 Cup seal

50 Shift fork

51 Tapered roller bearing outer race

52 Tapered roller bearing

53 Rear axle output shaft

54 Sliding block

55 Input shaft

56 Needle bearing

57 Planetary gear

58 Planetary gear carrier cover

59 Bolt

60 Shift sleeve

61 Shift gear

62 Shim

63 Bearing inner race half

64 Ball bearing

65 Bearing inner race half

66 Gasket

23 Sealing ring

24 Bolt

25 Locking ring

26 Rotary shaft seal

27 Coupling flange

28 Collared nut

29 Bolt

30 Front bracket

31 Locking ring

32 End cover

33 Locking ring

34 Rotary shaft seal

35 Coupling flange

36 Collared nut

37 Collared nut

38 Tapered roller bearing outer race

39 Tapered roller bearing

40 Front axle output shaft

41 Tapered roller bearing

42 Tapered roller bearing outer race

43 Tapered roller bearing outer race

44 Tapered roller bearing

	Removing
1	Drain oil from transfer case		AP28.00-D-2801A
2	Remove transfer case		AR28.10-D-0100D
	Dismantling
3	Unlock and unscrew collared nuts (1, 28, 36)	 Pin wrench	*717589003100
4	Remove coupling flanges (2, 27, 35)	 Puller	*035589013300
5	Remove rotary shaft seals (3, 26, 34)
6	Unscrew pressure switch (22)	 Remove sealing ring (23)
7	Unscrew banjo bolts (15)	 Remove oil line (14) and sealing rings (13, 16)
8	Unscrew front section of housing (21) and remove with rear bracket (19) and front bracket (30)	 Remove gasket (66)
9	Remove bearing inner race half (65)
10	Take out front axle output shaft (40) and intermediate shaft (45)
11	Remove bearing inner race half (63), shim (62), shift gear (61) and shift sleeve (60)
12	Remove input shaft (55)	 Remove sliding block (54)
13	Dismantle input shaft (55)	 Unscrew bolts (59) and planetary gear carrier cover (48), planetary gear (57) and needle bearing (56)
14	Hammer out rear axle output shaft (53) using a synthetic head hammer and remove with shift fork (50)	 Remove tapered roller bearing (4) and roll pin (6). Pull cup seals (49) off shift fork
15	Pull tapered roller bearing (52) off rear axle output shaft (53)	 Puller	*001589503300
		 Clamping pliers	*387589023400
16	Pull tapered roller bearings (44, 46) off intermediate shaft (45)	 Puller	*001589503300
		 Clamping pliers	*387589023400
17	Unlock and unscrew collared nut (37)	 Screw two propellor shaft bolts into coupling flange and clamp front axle output shaft with flange in vise.
18	Pull tapered roller bearing (39, 41) off front axle output shaft (40)	 Puller	*001589503300
		 Clamping pliers	*387589023400
19	Unscrew screw plug (11) from bearing cover (9)	 Remove sealing ring (12)
20	Unscrew bearing cover (9)	 Remove gasket (10)
21	Remove tapered roller bearing outer race (5)	 Internal extractor	*000589293300
		 Countering support	*000589343300
22	Remove end cover (32)
23	Remove locking rings (25, 31, 33)	 Pliers for locking ring	*WH58.30-Z-1009-02A
24	Remove ball bearing (64) and tapered roller bearing outer races (42, 47, 51)	 Drift punch	*389589011500
25	Remove tapered roller bearing outer races (38, 43)	 Internal extractor	*000589303300
		 Countering support	*000589343300
26	Remove bushes (48)	 Heat up the front and rear sections of the housing in the area outside the bush blind holes.
		 Internal extractor	*000589293300
		 Countering support	*000589343300