Disassembling transfer case · ar2810d1001c · Mercedes-Benz WIS

AR28.10-D-1001C

Disassembling transfer case

12.11.98

MODEL 903.0 /4, 904.0 /4 with CODE (ZG3) reduction ratio for all-wheel drive

D28.10-0019-09

D28.10-0020-09

1 Collared nut

2 Coupling flange

3 Rotary shaft seal

4 Tapered roller bearing

5 Tapered roller bearing outer race

6 Roll pin

7 Bolt

8 Washer

9 Bearing cover

10 Gasket

11 Screw plug

12 Sealing ring

13 Sealing ring

14 Oil line

15 Banjo bolt

16 Sealing ring

17 Nut

18 Washer

19 Rear bracket

20 Rear section of housing

21 Front section of housing

22 Pressure switch

23 Sealing ring

24 Speedometer pulse generator socket

25 O-ring

26 Pressure switch

27 Sealing ring

55 Gasket

56 Tapered roller bearing outer race

57 Tapered roller bearing

58 Intermediate shaft

59 Idler gear

60 Tapered roller bearing

61 Tapered roller bearing outer race

62 Bolt

63 Bush

64 Cup seal

65 Shift fork

66 Tapered roller bearing outer race

67 Tapered roller bearing

68 Rear axle output shaft

69 Sliding block

70 Needle bearing

71 Shift sleeve

72 Input shaft

73 Needle bearing

74 Needle bearing

75 Shift gear

76 Shim

77 Bearing inner race half

78 Ball bearing

79 Bearing inner race half

28 Bolt

29 Locking ring

30 Rotary shaft seal

31 Coupling flange

32 Collared nut

33 Bolt

34 Front bracket

35 Locking ring

36 End cover

37 Locking ring

38 Rotary shaft seal

39 Coupling flange

40 Collared nut

41 Bush

42 Cup seal

43 Shift fork

44 Collared nut

45 Tapered roller bearing outer race

46 Tapered roller bearing

47 Thrust washer

48 Output gear

49 Needle bearing

50 Needle bearing

51 Front axle output shaft

52 Shift sleeve

53 Tapered roller bearing

54 Tapered roller bearing outer race

	Removing
1	Drain oil from transfer case		AP28.00-D-2801A
2	Remove transfer case		AR28.10-D-0100C
	Dismantling
3	Unlock and unscrew collared nuts (1, 32, 40)	 Pin wrench	*717589003100
4	Remove coupling flanges (2, 31, 39)	 Puller	*035589013300
5	Remove rotary shaft seals (3, 30, 38)
6	Unscrew pressure switches (22, 26)	 Remove sealing rings (23, 27)
7	Unscrew banjo bolts (15)	 Remove oil line (14) and sealing rings (13, 16)
8	Unscrew front section of housing (21) and remove with rear bracket (19) and front bracket (34)	 Remove gasket (55)
9	Remove bearing outer race half (79)
10	Dismantle input shaft (72)	 Remove bearing inner race half (77), shim (76), shift gear (75) and needle bearing (73, 74)
11	Remove input shaft (72)	 Remove sliding block (69), needle bearing (70) and shift sleeve (71)
12	Remove front axle output shaft (51) with intermediate shaft (58) and shift fork (43)	 Pull cup seals (42) off the shift fork
13	Dismantle front axle output shaft (51)		AR28.50-D-1000-03A
		 Puller	*001589503300
		 Clamping pliers	*387589023400
14	Unscrew bolt (62) from intermediate shaft (58)
15	Pull tapered roller bearings (57, 60) off intermediate shaft (58)	  Screw bolt M10 x 1.5 into intermediate shaft ensuring that the thread is not damaged	*001589503300
		 Clamping pliers	*387589023400
16	Pull off idler gear (59)	 Puller	*000589893300
17	Hammer out rear axle output shaft (68) using a synthetic head hammer and remove with shift fork (65)	 Remove tapered roller bearing (4) and roll pin (6). Pull cup seals (64) off shift fork
18	Pull tapered roller bearing (67) off rear axle output shaft (68)	 Puller	*001589503300
		 Clamping pliers	*387589023400
19	Unscrew screw plug (11) from bearing cover (9)	 Remove sealing ring (12)
20	Unscrew bearing cover (9)	 Remove gasket (10)
21	Remove tapered roller bearing outer race (5)	 Internal extractor	*000589293300
		 Countering support	*000589343300
22	Remove speedometer pulse generator socket (24)	 Remove O-ring (25)
23	Remove end cover (36)
24	Remove locking rings (29, 35, 37)	 Pliers for locking ring	*WH58.30-Z-1009-02A
25	Remove ball bearing (78) and tapered roller bearing outer races (54, 61, 66)	 Drift punch	*389589011500
26	Remove tapered roller bearing outer races (45, 56)	 Internal extractor	*000589303300
		 Countering support	*000589343300
27	Remove bushes (41, 63)	 Heat up the front and rear sections of the housing in the area outside the bush blind holes.
		Internal extractor	*000589293300
		 Countering support	*000589343300