Remove/install transfer case

AR28.10-P-0100GZ

Remove/install transfer case

2.11.11

25.6.07

Special tool for counterholding the propeller shaft modified

AR41.10-P-0070-03GZ

Observe tightening procedure when assembling propeller shaft, added

Operation step 7

 

Remove/install

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Secure vehicle on the lifting platform and raise

AR00.60-P-0100GZ

2

Remove bottom part of rear soundproofing

Vehicles with diesel engine

3.1

Disconnect exhaust system to flange connection between catalytic converter and center muffler

Vehicles with gasoline engine

Engine 113

AR49.10-P-7000GZ

Engine 156

AR49.10-P-7000GZS

Engine 272, 273

AR49.10-P-7100GZA

3.2

Separate exhaust system at hose clamp between diesel particulate filter and pipeline

Vehicles with engine 642

AR49.10-P-7100GZB

3.3

Separate exhaust system at hose clamp and at flange connection between diesel particulate filter and pipeline

Vehicles with engine 629

AR49.10-P-7100GZB

4

Detach heat shield from transfer case (15)

Vehicles with offroad package code 430

5

Detach transfer case actuator motor connector (3), detach transfer case absolute sensor connector (B57x1) and transfer case switchover valve connector (Y108x1)

Vehicles with offroad package code 430

6

Mark position of propeller shaft (4) relative to flange of transfer case (15)

7

Undo rear propeller shaft (4) at output flange to rear axle on transfer case (15)

 Installation: Observe tightening procedure for rear propeller shaft (4) to transfer case (15).

AR41.10-P-0050-17GZ



*BA41.10-P-1001-01F



*164589020700

8

Remove bolts (6) and nuts (7), remove bracket (5)

Vehicles with engine 629, 642

 Model 164.8, left and right brackets (5).



*BA49.10-P-1003-01U



*BA49.10-P-1012-01U

9

Detach bracket from pressure measuring hoses and pressure sensors

Vehicles with engine 629



*BA49.10-P-1012-01U

10

Remove bolts (2), remove cross strut (1)



*BA22.10-P-1006-03G



*BA22.10-P-1008-03G

11

Disconnect diagonal strut from transmission suspension (8) and frame floor assembly



*BA22.10-P-1007-03G



*BA22.10-P-1009-03G

12

Mark position of front propeller shaft (11) relative to flange of transfer case (15)

13

Detach front propeller shaft (11) on output flange to front axle

 Installation: Observe tightening procedure for front propeller shaft .

AR41.10-P-0070-03GZ



*BA41.10-P-1003-01F



*164589020700

14

Use support brace to prop up transfer case (15) on housing (13)

15

Remove bolts (9, 10) and remove transmission suspension (8)



*BA22.10-P-1004-03G



*BA22.10-P-1005-03G

16

Remove lower four bolts (16) on transfer case (15)



*BA28.10-P-1002-01A

17

Remove support brace (13) from housing of transfer case (15) and attach to rubber mount (12), support transfer case (15) with transmission jack and transmission platform (14)

Telescopic transmission jack

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

18

Slowly lower drivetrain slightly until the upper bolts (16) on the transfer case (15) are accessible

19

Remove upper four bolts (16) on transfer case (15)



*BA28.10-P-1002-01A

20

Slide transfer case (15) rearwards until transfer case (15) is separated completely from the transmission, lower transfer case (15)

 Move the transfer case input shaft (15) completely out of the transmission.

 Installation: Slightly grease toothing of transfer case input shaft (15).

MB long-life grease

*BR00.45-Z-1001-06A

21

Install in the reverse order

22

Check oil quantity in transfer case (15) and correct if necessary



*BA28.10-P-1001-01A

 Transmission oil

*BF28.10-P-1001-01E

23

Perform calibration using STAR DIAGNOSIS, read out fault memory and erase if necessary

 Menu item: Transfer case Control units adaptations Calibration.

Number

Designation

Model
164

BA22.10-P-1004-03G

Bolt/nut, connecting rear engine mount to rear engine crossmember

Nm

58

BA22.10-P-1005-03G

Bolt, rear engine crossmember to body

Nm

55

BA22.10-P-1006-03G

Bolt, cross strut to engine crossmember

Nm

45

BA22.10-P-1007-03G

Bolt, diagonal strut to engine crossmember

Nm

45

BA22.10-P-1008-03G

Bolt, cross strut to body

Nm

45

BA22.10-P-1009-03G

Bolt, diagonal strut to body

Nm

45

Number

Designation

Model
164.1/8

BA28.10-P-1001-01A

Screw plug to transfer case

Nm

25

BA28.10-P-1002-01A

Bolt, transfer case to automatic transmission

Nm

45

Number

Designation

Model
164.1/8

BA41.10-P-1001-01F

Self-locking bolt for propellor shaft on transfer case (to rear axle)

Stage 1

Nm

40

Stage 2

°

90

BA41.10-P-1003-01F

Self-locking bolt, propellor shaft to transfer case (to front axle)

Stage 1

Nm

40

Stage 2

°

90

Number

Designation

Engine
642
in model
164
without Code U42

Engine
629.912
in model
164

BA49.10-P-1003-01U

Self-locking nut, diesel particulate filter to transfer case bracket

Nm

20

-

BA49.10-P-1012-01U

Bolt, transfer case bracket to transfer case

Nm

34

34

Number

Designation

Model
164, 166
Single-speed

Model
164, 166
Double-speed

BF28.10-P-1001-01E

Gear oil

Filling capacity

Liters

0.5

1.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0236-12A

BB00.40-P-0236-12A

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11