Disassembling and assembling differential lock shift cylinder

AR35.40-P-9135F

04.09.2018

Model	460
Model	461 (except 461.331)
Model	463 (except 463.270/271)
	up to model year 2013

Disassembling and assembling differential lock shift cylinder

1	Pressure switch
2	Shift cylinder housing
3	Gearshift lever
4	Switch spring
5	Shift shaft
6	Return spring
7	Washer
8	Retaining ring
9	Compression spring
10	Dust boot
11	Seal boot
12	Piston
13	Seal
14	Cover
15	Screw
16	Vent valve

D35.40-0008-06

	Remove
 Caution	Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid	Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.	AS42.50-Z-0001-01A
Topical note	Brake fluid notes		AH42.50-P-0001-01A
1	Remove shift cylinder on differential lock		AR35.40-P-9131F
 	Disassemble/assemble
2	Unscrew pressure switch (1)	 Assembly: Only tighten pressure switch (1) to 1st stage.
		 Pressure switch to shift cylinder	*BA35.40-P-1005-01A
		 Socket wrench bit	*620589010900
3	Detach cap (14)	 Undo bolts (15) from cover (14), spring-loaded.
		 Assembly: Install new seal (13).
		 Bolt, cover to shift cylinder	*BA35.40-P-1002-01A
4	Remove piston (12) and push spring (9)	 Assembly: Replace dust boot (10) and seal boot (11), observe installation position. Coat dust boot (10), seal boot (11) and piston (12) with MB silicone grease.
		ABS sensor grease	*BR00.45-Z-1019-06A
5	Unscrew shift shaft (5) from shifter lever (3)	 Assembly: Apply quick-action adhesive to the thread of the shift shaft (5).
		 Shift shaft to gearshift lever for cross-axle differential lock	*BA35.40-P-1003-01A
		Quick-acting adhesive, Loctite 270	*BR00.45-Z-1008-02A
6	Remove gearshift lever (3) and shift shaft (5) with switch spring (4) from the shift cylinder housing (2)
7	Disassemble shift shaft (5)	 To facilitate dismantling of the separate parts screw the gearshift lever (3) onto the shift shaft (5) and clamp in vise.
		 Assembly: Circlip (8) must engage in the groove. To facilitate assembly of separate parts screw the gearshift lever (3) onto the shift shaft (5) and clamp in vise.
		 Clamping device	*381589003100
	Clean
8	Clean all parts	Cold degreasing agent/cold cleaning solvent HAKU 1025-920	*BR00.45-Z-1051-04A
	Check
9	Check all parts for wear and damage, replace if necessary
10	Assemble in the reverse order
	Install
11	Install shift cylinder for differential lock		AR35.40-P-9131F
12	Tighten pressure switch (1)	 Tighten pressure switch (1) with the 2nd stage.
		 Pressure switch to shift cylinder	*BA35.40-P-1005-01A

 Differential lock shift cylinder

Number	Designation		Model 460, 461 Model 463 up to model year 2019	Model 463 as of model year 2019
BA35.40-P-1002-01A	Bolt, cover to shift cylinder	Nm	20	-

 Differential lock shift cylinder

Number	Designation		Model 460, 461 Model 463 up to model year 2019	Model 463 as of model year 2019
BA35.40-P-1003-01A	Shift shaft to gearshift lever for cross-axle differential lock	Nm	25	-

 Differential lock shift cylinder

Number	Designation			Model 460, 461 Model 463 up to model year 2019	Model 463 as of model year 2019
BA35.40-P-1005-01A	Pressure switch to shift cylinder	Stage 1	Nm	20	-
		Stage 2	Nm	105	-

620 589 01 09 00

Socket wrench bit

381 589 00 31 00

Clamping device

Repair materials

Number	Designation	Order number
BR00.45-Z-1008-02A	Quick-acting adhesive, Loctite 270	A 002 989 93 71
BR00.45-Z-1019-06A	ABS sensor grease	A 000 989 62 51 10
BR00.45-Z-1051-04A	Cold degreasing agent/cold cleaning solvent HAKU 1025-920	Chemische Werke Kluthe GmbH Gottlieb-Daimler-Str. 12 69115 Heidelberg Germany Tel. +49 6221 5301-0 Fax +49 6221 5301-176 http://kluthe.com

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