AR28.10-D-1002-01B | Attach housing front section | Models 903.0/4, 904.0/4 with code ZG3 | |
| Circlip set for determining circlip thickness |
Transfer case housing
Number | Designation | 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 |
D28.10-0022-11
1 Place new seal on the housing rear part.
2 Pull shift fork (65) upwards and fix in place using a screwdriver (81).
D28.10-0009-11
3 Mount housing front part.
After the shift fork piston has been inserted in the bushing of the housing front part, pull out the screwdriver.
4 Position front bracket (18) and rear bracket (7).
Observe installation position:
The protruding bushing pieces must point outwards.
5 Tighten the housing front part with every second bolt (12, 17), .
Insert long bolts (17) in the brackets (7, 18).
D28.10-0010-01
6 Using a plastic hammer knock gently on the housing front part until the pre-tension of the bearings has released.
It must be possible to turn the tapered roller bearings.
7 Using retaining ring set (48), determine the distance between the outer rings and upper edge of the groove.
D28.10-0011-11
8 Loosen nuts and install retaining rings (13, 19) with the following dimensions:
Thickness = measured value + 0.25 mm
Pay attention to correct seating of the retaining rings.
9 Install retaining ring (21) with the following dimension:
Thickness = measured value
Ensure that the circlip is properly seated.
10 Insert remaining bolts (12, 17) with washers and nuts.
Insert long bolts (17) in the brackets.
11 Tighten nuts, .
12 In the area of the retaining rings knock gently on the housing front part using a plastic mallet.
With this operation step it is ensured that the tapered roller bearing outer races abut the retaining ring.