Remove/install transfer case

AR28.10-P-0100OIB

05.05.2020

Transmission	725.0 in model 257 with engine 656
	with code M005 (Vehicles with 4MATIC/all-wheel drive)

2	Rear engine mount
3	Propeller shaft
4	Front axle transmission propeller shaft
5	Transmission
9	Vibration damper

P28.10-2328-05

6	Bolts
7	Transfer case

P28.10-2302-12

5	Transmission
6	Bolts
7	Transfer case
8	Intermediate panel
9	Vibration damper
10	Bolts

P28.10-2322-04

 Danger	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
 Caution	Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil	Wear protective gloves, protective clothing and safety glasses. Do not pour transmission oil into beverage bottles.	AS00.40-Z-0001-01A
 Caution	Risk of injury caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
Topical note	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
Topical note	Notes on threaded connections with aluminum screws/bolts		AH00.00-P-0006-01RM
	Notes on automatic transmission		AH27.19-P-0001-01NKB
 	Remove/install
1	Secure vehicle on vehicle lift.		AR00.60-P-0100-01A
		 Vehicle hoist securing tool	*171589013100
2	Shift the transmission (5) into neutral position.
3	Release parking brake.
4	Remove exhaust system.		AR49.10-P-7142OIB
5	Remove heat shield behind the transmission (5).
6	Remove propeller shaft (3) from output flange of transfer case (7), slide backward and secure against falling down.		AR41.10-P-0040-01MSA
	Drift for releasing the fitting sleeves in the flexible couplings		WF58.50-P-4110-01A
		 Flexible coupling to transmission/rear axle differential or propeller shaft	*BA41.10-P-1001-01M
		 Counterholder	*176589004000
7	Remove rear engine mount (2).		AR22.10-P-1160OIB
8	Remove screws (10) and remove vibration damper (9).	 Bolt, vibration damper to transfer case	*BA28.10-P-1008-01G
9	Support transfer case (7).
	000 588 10 62 00 Support plate		WS26.00-P-3309B
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
10	Lower transmission (5) until all screws (6) on the circumference of the transfer case (7) are accessible.
11	Remove screws (6) and remove transfer case (7).	 Installation: Before mounting the transfer case (7) coat the gearing of the transmission's output shaft (5) with grease.
		 Installation: Replace screw/bolts (6).
		 The aid of a second person is required for disconnection and connection at the flange of the front axle propeller shaft(4).
		Klueber Microlube GNY 202	*BR00.45-Z-1071-06A
		 Bolt, transfer case to automatic transmission	*BA28.10-P-1001-01G
12	Check intermediate panel (8) for damage.	If damage is found,
		
		Replace intermediate panel(8).
13	Install in the reverse order.
14	Check and correct oil level of transfer case (7).		AR28.10-P-0100-06A
		 Transfer case oil	*BF28.10-P-1001-01F
		 Oil level sight glass to transfer case	*BA28.10-P-1007-01G
		 Drain screw to transfer case	*BA28.10-P-1003-01G
		Assembly cleaner	*BR00.45-Z-1028-04A
		 Hand pump	*210589007100
15	Check transfer case (7) for proper operation and leak tightness.

 Complete transfer case

Number	Designation			Model 205, 213, 217, 218, 222, 223, 238, 253, 257, 290 with transmission 725.0/1 with code M005 (Vehicles with 4MATIC/all-wheel drive)
BA28.10-P-1001-01G	Bolt, transfer case to automatic transmission	Stage 1	Nm	30
		Stage 2	°	90

 Complete transfer case

Number	Designation		Model 205, 213, 217, 218, 222, 223, 238, 253, 257, 290 with transmission 725.0/1 with code M005 (Vehicles with 4MATIC/all-wheel drive)
BA28.10-P-1003-01G	Drain screw to transfer case	Nm	25

 Complete transfer case

Number	Designation		Model 205, 213, 217, 218, 222, 223, 238, 253, 257, 290 with transmission 725.0/1 with code M005 (Vehicles with 4MATIC/all-wheel drive)
BA28.10-P-1007-01G	Oil level sight glass to transfer case	Nm	11

 Complete transfer case

Number	Designation		Model 205, 213, 217, 218, 222, 223, 238, 253, 257, 290 with transmission 725.0/1 with code M005 (Vehicles with 4MATIC/all-wheel drive)
BA28.10-P-1008-01G	Bolt, vibration damper to transfer case	Nm	39

 Propeller shaft

Number	Designation				Model 257
BA41.10-P-1001-01M	Flexible coupling to transmission/rear axle differential or propeller shaft	Direct threaded connection	Stage 1	Nm	60
			Stage 2	°	90

 Complete transfer case

Number	Designation			Models 205, 213, 217, 218, 222, 238, 253, 257, 290 with transmission 725.0
BF28.10-P-1001-01F	Transfer case oil	Filling capacity	Liter	0,65
		Sheet		BB00.40-P-0236-15A

210 589 00 71 00

Hand pump

176 589 00 40 00

Counterholder

171 589 01 31 00

Vehicle hoist securing tool

Repair materials

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01
BR00.45-Z-1071-06A	Klueber Microlube GNY 202	A 001 989 44 51 10

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