Assemble transfer case

AR28.10-D-1002C

Assemble transfer case

16.10.09

29.11.07

Value changed: Gear oil, filling capacity for oil change

*BF28.10-N-1001-01D

Value changed: Gear oil , Specifications for Operating Fluids

*BF28.10-N-1001-01D



Assemble

1

Install tapered roller bearing outer races (54, 61)



 Use the bearing with total height

21 mm.

 Drive in the outer races from inside so that they are flush with the housing.

*460589151500

2

Install tapered roller bearing outer races (45, 56)

 Use the bearing with total height

21 mm.

 Drive the tapered roller bearing outer races all the way into the housing from inside.

*389589011500

3

Clean sealing surfaces of housing parts (20, 21) and bearing cap (9)

4

Attach bearing cover (9)

 Tighten bolts (7) with washers (8) evenly in crosswise sequence

*BA28.40-N-1004-01E

 Replace seal

5

Install tapered roller bearing outer race (66)

  Use the bearing with total height 18.5 mm.

 Drive the tapered roller bearing outer race all the way into the housing from inside.

*389589011500

6

Install tapered roller bearing outer race (5)

 Drive the tapered roller bearing outer race all the way into the housing.

*343589021500

7

Install bushings (41, 63)

AR28.10-D-1002-02A

Sealant

*BR00.45-Z-1026-01A

8

Prepare shift forks (43, 65) for installation

AR28.50-D-1002-02A

Sealant

*BR00.45-Z-1026-01A

Lubricant

*BR00.45-Z-1001-06A

9

Install rear axle output shaft (68)

AR28.50-D-1002-01A

Friction torque

*BE28.50-N-1001-01C

 Drift

*387589061500

 Drift

*750589021500

 Torque meter

*001589492100

 Retainer wrench

*717589003100

Heating plate

10

Install speedometer pulse generator bushing (24)

 Replace the O-ring (25). Press in sleeve using socket (SW10)

11

Place intermediate gear (59) on intermediate shaft (58)

 Heat up the intermediate gear to

125 °C.

12

Place tapered roller bearing (57, 60) on intermediate shaft (58)

 Heat up the tapered roller bearing to

125 °C.

  Position using a drift if necessary.

*460589151500

13

Assemble front axle output shaft (51)

AR28.50-D-1000-04A



*BA28.50-N-1001-01B

 Drift

*460589151500

 Heat up the tapered roller bearing to

125 °C.

14

Secure collar nut (44)

AR33.30-D-0085-03A

15

Insert front axle output shaft (51) with shift fork (43) and intermediate shaft (58) into housing rear section (20)

 Make sure that the shift fork is fitted at the correct position.

16

Install needle bearing (70) and shift collar (71)

 Make sure that the shift collar is fitted at the correct position:

The long collar must point toward the transmission.

17

Place input shaft (72) with sliding disk (69) on rear axle output shaft (68)

 The lubricating grooves of the sliding disk must point toward the input shaft.

 Bond the sliding disk to the input shaft using oil.

18

Assemble (72) drive shaft

 Fit the needle bearings (73, 74), shifting gear (75) and shim (76).

19

Place bearing inner race half (77) on input shaft (72)

 Heat up the bearing inner race half to

125 °C.

  Position using a drift if necessary.

*000589101500

20

Insert ball bearing (78) into housing front section (21)

  Press in the ball bearing from outside until the groove in the housing is fully visible.

*389589011500

21

Attach housing front section (21)

AR28.10-D-1002-01B



*BA28.40-N-1003-01E

Retaining ring pliers



Retaining ring set for determining retaining ring thickness

WF58.50-N-2810-01A

22

Fit bearing inner race half (79)

 Heat up the bearing inner race half to

125 °C.

  Position using a drift if necessary.

*000589101500

23

Install radial shaft sealing rings (30, 38)

  Replace the radial shaft sealing rings.

*750589021500

24

Install cap (36)

 Replace the cap.

25

Install connector flange (31, 39)

  Replace the collar nuts.

*BA28.10-N-1006-01C

 Retainer wrench

*717589003100

26

Tighten pressure switches (22, 26)

  Replace the seal ring. Large pressure switch for input shaft

*BA28.19-N-1003-01B

27

Install oil line (14)

  Renew seals

*BA28.10-N-1008-01C

28

Fill bearing cap (9) with oil and install screw plug (11)



*BF28.10-N-1001-01D

  Fit new sealing ring

*BA28.10-N-1009-01C

29

Secure collar nuts (1, 32, 40)

AR33.30-D-0085-03A



Install

30

Install transfer case.

AR28.10-D-0100C

31

Pour oil into transfer case

AP28.00-D-2801A

Number

Designation

Model 903.0/4, 904.0/4 with code ZG2/ZG3

BE28.50-N-1001-01C

Friction torque of rear axle output shaft

Nm

1,5-2,0

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

BA28.40-N-1004-01E

Bolt, bearing cap to rear of housing

Nm

12

Number

Designation

Model 903.0/4, 904.0/4
with code ZG1/ZG3

BA28.50-N-1001-01B

Nut to front axle output shaft

Nm

200

Number

Designation

Model 903.0/4, 904.0/4 with code ZG2/ZG3

BA28.10-N-1006-01C

Nut, coupling flange to transmission/to front axle to transfer case

M261.5

Nm

300

BA28.10-N-1008-01C

Banjo bolt, oil line to housing

M101

Nm

15

BA28.10-N-1009-01C

Bearing cap screw plug

M101

Nm

10

Number

Designation

Models 903.0/4/6, 904.0/4/6
with code ZG2/ZG3

BA28.19-N-1003-01B

Temperature sensor to housing

Nm

9

Number

Designation

Models 903.0/4/6, 904.0/4/6 with code ZG2/ZG3

BF28.10-N-1001-01D

Gear oil

Filling capacity for oil change

Liters

1.0

Filling capacity for complete refill (with bearing cap filling)

Liters

1.0

Specifications for Operating Fluids

Sheet

BB00.40-P-0236-12A

Number

Designation

Order number

BR00.45-Z-1026-01A

Terostat 33 sealant

A 001 989 61 20

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11