A. Removal and Installation of Sun Gear Shaft

Dismantling and Assembling Transfer Case

Preceding work:
Transfer case removed (28-200) Removal and Installation of Transfer Case


A. Removal and Installation of Sun Gear Shaft

Special Tools:

Detach locating plate 124 589 22 63 00 to assembling trestle 116 589 06 59 00 (number 1).

Mount internal-geared wheel (124 589 22 63 04 up to tranmission no 7012, 124 589 22 63 14 as of transmission no 7013) on the planet carrier (29). Note dowel pins (number 2)

Unscrew bolts (33); 55 Nm. Remove oil cooler pipe (34). Replace gasket (33a) (number 3)

Unscrew hydraulic connection of center differential lock (ZS) and front axle drive train (AV)

Unscrew collar nut (35), 160 Nm. Replace and secure (number 3). Use socket wrench 126 589 02 09 00.

Detach joint flange (11) (number 3)

Unscrew bolts (54), 20 Nm. Remove vibration tilger (10) (mumber 4)

Unscrew bolts (53), 28 Nm.
Withdraw transmission housing cover (32) and bracket (55). Clean sealing surfaces, lightly lubricate sealing lip and contact point of radial sealing ring. Replace gasket (58) (number 5).
Note: The transmission housing cover is fixed with two dowel pins.

Remove bolts (46). Remove snap ring (46a) with pliers 000 589 52 37 00. Pull out planet gear shaft (29) (number 6). To install, mount internal-geared wheel 124 589 23 63 04 or 124 589 22 63 14 on the planet gear shaft (29).

Insert thrust pad 124 589 22 63 12. Screw on strip 124 589 22 63 06. Preload sun gear shaft (7), remove circlip (37) (number 7, 8 and 10).

Remove inner multi-disk carrier of front axle drive train (AV) (60), thrust washer (45) and axial bearing (44) (number 9).

Unscrew strip 124 589 22 63 06. Remove sun gear shaft (7) whilst noting the balls (85) (12 off) (number 10).

Remove axial bearing (81), thrust washers (80 and 84) and balls (65) (12 off) (number 10).


Removal and installation




1 Mount locating plate (02) 124 589 22 63 00 on assembly trestle (01) 116 589 06 59 00 and fasten transfer case to locator (02).




2 Mount internal-geared wheel (03) on planet gear carrier (29). The dowel pins (arrows) must engage in the locator plate.

Note:Use internal-geared wheel 124 589 22 63 04, up to transmission no.7012 and internal-geared wheel 124 589 22 83 14 as of transmission no.7013.




3 Unscrew banjo bolts (33). Remove oil cooler pipe (34). Unlock collar nut (35) and unscrew using socket wrench bit 126 589 02 09 00. Withdraw joint flange (11).

Installation note
Replace oil cooler pipe gaskets (33).
Tightening torque: Banjo bolts (33): 55 Nm, Collar nut (35): 160 Nm.




4 Unscrew bolt (54). Remove vibration tilger (10).
Installation note
Tightening torque 20 Nm.




5 Unscrew bolts (53), remove bracket (55). Withdraw transmission housing cover (32).
Note: The transmission housing cover is located with two dowel pins.
Installation note
Clean sealing surface of transmission housing and transmission housing cover (32). Replace gasket.
Lightly lubricate sealing lip of radial sealing ring and contact point on the planet gear shaft.
Tightening torque 28 Nm.




6 Swivel transmission to the horizontal. Remove retaining ring (46). Remove snap ring (46a) using pliers 000 589 52 37 00. Withdraw planet gear shaft (29).




Installation note
Mount internal-geared wheel (03)124 589 22 63 04 or 126 589 22 63 14 on the planet gear shaft (29) and install together in the transmission housing.




7 Swivel transmission through 90°. Insert thrust pad (028)124 589 22 63 12 into the sun gear shaft (7). Screw on strip (09)124 589 22 63 06. Pre-load sun gear shaft (center differential lock (ZS) clutch) with bolt (arrow) until circlip (37) is released.




8 Position transmission upright (multi-disk clutch of front axle drive train (AV) upwards). Remove circlip (37) with circlip pliers.




9 Remove inner multi-disk carrier of front axle drive train (AV) (60), thrust washer (45) and axial bearing (44).




10 Unscrew strip bracket (09)124 589 22 63 06, secure sun gear shaft (7) and thrust pad (028) 124 589 22 63 12, remove downwards.
Note: Ensure that the 12 balls do not fall out.




Installation note
Position transmission upright (multi-disk clutch of front axle drive train (AV) upwards). Push in sun gear shaft (7) complete with 12 balls, thrust washers and axial bearing from below. Swivel transmission through 180°.