Assemble transfer case

AR28.10-D-1002D

Assemble transfer case

15.1.10

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 (42, 47)

  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 (38, 43)

  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 (51)

  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 (48)

AR28.10-D-1002-02A

Sealant

*BR00.45-Z-1026-01A

8

Prepare shift fork (50) 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 (53)

AR28.50-D-1002-01B

Friction torque

*BE28.50-N-1001-01C

 Drift

*387589061500

 Drift

*750589021500

 Torque meter

*001589492100

 Retainer wrench

*717589003100

Heating plate

10

Place tapered roller bearing (44, 46) on intermediate shaft (45)

 Heat up the tapered roller bearing to

125 °C.

  Position using a drift if necessary.

*460589151500

11

Place tapered roller bearings (39, 41) on front axle output shaft (40) and tighten collar nut (37)

 Heat up the tapered roller bearing to

125 °C.

  Position using a drift if necessary.

*460589151500



*BA28.50-N-1001-01B

12

Secure collar nut (37)

AR33.30-D-0085-03A

13

Assemble (55) drive shaft

  Fit the needle bearing (56), planetary gears (57) and planet carrier cap (58) and secure with the bolts (59).

*BA28.50-N-1002-01B

14

Place input shaft (55) with sliding disk (54) on rear axle output shaft (53)

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

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

15

Place shift collar (60) with shifting gear (61) on input shaft (55)

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

The wider collar must point toward the transmission.

16

Place shim (62) and bearing inner race half (63) on input shaft (55)

 Heat up the bearing inner race half to

125 °C.

  Position using a drift if necessary.

*000589101500

17

Insert front axle output shaft (40) and intermediate shaft (45) into housing rear section (20)

18

Insert ball bearing (64) into housing front section (21)

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

*389589011500

19

Attach housing front section (21)

AR28.10-D-1002-01C



*BA28.40-N-1003-01E

Retaining ring pliers



Circlip set for determining circlip thickness

WF58.50-N-2810-01A

20

Fit bearing inner race half (65)

 Heat up the bearing inner race half to

125 °C.

  Position using a drift if necessary.

*000589101500

21

Install radial shaft sealing rings (26, 34)

  Replace the radial shaft sealing rings.

*750589021500

22

Install cap (32)

 Replace the cap.

23

Install connector flange (27, 35)

  Replace the collar nuts.

*BA28.10-N-1006-01C

 Retainer wrench

*717589003100

24

Secure collar nuts (1, 28, 36)

AR33.30-D-0085-03A

25

Tighten pressure switch (22)

  Fit new sealing ring

*BA28.19-N-1003-01B

26

Install oil line (14)

  Renew seals

*BA28.10-N-1008-01C

27

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



Install

28

Install transfer case.

AR28.10-D-0100D

29

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

Models 903.0/4, 904.0/4
with code ZG2

BA28.50-N-1001-01B

Nut to front axle output shaft

Nm

200

BA28.50-N-1002-01B

Bolt, planet carrier cap to input shaft

Nm

30

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