Removal and Installation of Transfer Case

Removal and Installation of Transfer Case

Special Tools:

Removal

Disconnect battery ground cable.

Cover insulating mat in component compartment panel with a suitable sheet metal part.

Remove Bowden cable (98).

Relocate service valve in "Test" position (up to transfer case no.26 616)

Relocate coding plug in "Test" position (as of transfer case no.26 617)

Loosen pressure relief screw (16) at the valve control unit, thus reducing the storage pressure of the complete system (as of transfer case no.26 617).

Remove oil dipstick guide tube (15).

Remove exhaust system (100). Removing and Installing Exhaust System

Remove exhaust side support (24).

Remove shields (3) and (4).

Remove transverse bridge (31). Hexagon bolts (32 and 33), 25 Nm.

Drain oil from transfer case (201). Capacity 0.7 liter.

Unscrew propeller shaft (7). Hexagon bolts (25), 60 Nm, loosen sleeves in joint flange. Replace self locking hexagon nuts (26).

Slacken propeller shaft intermediate bearing (202), 25 Nm.

Slacken prevailing torque type self-locking nut (200), 35 to 40 Nm. Use Torque wrench 001 589 66 21 00, and open-ended wrench 126 589 00 01 00.

Push together propeller shaft (7).

Remove pressure oil line of multi-disk clutch for front axle drive train (AV) and center differential (ZS); seal openings with blind plugs, check lines for leaks. Sealing plug kit 129 589 00 91 00.

Support transmission (10) with vehicle hoist or pit lift.

Unscrew rear engine mount (22), hexagon bolt (23b) and washers (23a) 40 Nm, hexagon bolts (23c) 20 Nm.

Unscrew front propeller shaft (40). Hexagon bolts (44) 40 Nm, loosen fitting sleeves in joint flange. Replace self-locking hexagon nuts (43).

Slacken prevailing torque type self-locking nut (40a), 30 to 40 Nm. Use torque wrench 001 589 66 21 00, and open-ended wrench 201 589 00 01 00.

Pull apart front propeller shaft (40).

Unclip shift lever (9).

Unscrew transfer case hexagon bolts (21), note different lengths, 25 - 30 Nm.

Draw out transfer case (201).


Installation

Replace gasket.

Insert transfer case horizontally at the internal geared wheel.

Installation is reverse of removal.

After installing the transfer case, Bleed complete system. Bleeding Hydraulic System


Note
As of transfer case no. 7 013, the teeth (straight) in the center differential have been modified. Previous internally-geared wheels cannot be combined with internally-geared wheels of the modified design when the transfer case is changed.

If transfer cases are ordered with the old part number, a transfer case with the modified teeth and associated internally-geared wheel will be supplied. In these cases the internally geared wheel is to be changed at the same time.