Transfer Case 0BU, Front Final Drive 0BM, 0C1 and 0BN, Rear Final Drive 0B (0C8A,0BNH,0BPH,0BMV,0C1V Transmission)

Repair Information

To perform a problem-free and successful transmission repair, extreme caution and cleanliness, as well as properly functioning tools are an important requirement. Understandably, general safety guidelines apply when performing repairs.

A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points in the Repair Manual, are summarized here.

Transmission

• Make sure that when installing the transfer case, you position the alignment sleeves properly between the transfer case and the transmission.

• Clean the contact surfaces before installing the brackets and waxed components. Contact surfaces must be free of wax and grease.

• Allocate bolts and other components via the Parts Catalog.

• Top off the transmission fluid up to the lower edge of the filler hole when replacing the transfer case, refer to => [ Gear Oil Level in the Transfer Case, Checking ] Gear Oil Level In the Transfer Case, Checking.

• Capacity and specification in the transfer case, refer to => [ Transfer Case 0BU Designation ] Transfer Case 0BU Designation.

• Top off the gear oil up to the lower edge of the filler hole when replacing the front final drive, refer to => [ Axle Oil Level, Checking ] Axle Oil Level, Checking.

• Capacity and specification for the front final drive; refer to => [ Front Final Drive 0BM and 0C1 Code Letters, Allocation, Ratios and Capacities ] Front Final Drive 0BM and 0C1 Code Letters, Allocation, Ratios and Capacities.

• Top off the gear oil up to the lower edge of the filler hole when replacing the rear final drive, refer to => [ Axle Oil Level, Checking ] Axle Oil Level, Checking.

• Capacity and specification for the rear final drive, refer to => [ Rear Final Drive 0BN, 0BP Identification ] Rear Final Drive 0BN, 0BP Identification.

Sealant

• Clean thoroughly before applying the sealant to the housing separating surfaces.

• Apply the sealant (AMV 174 004 01) evenly and not too thickly.

O-rings, Seals, Shaft Seals and Gaskets

• Replace O-rings.

• The open side on the shaft seals faces the fluid to be sealed off.

• Press the new shaft seals in enough so that the sealing lip is not on the same spot as the sealing lip for the old seal (use the press-in depth tolerance).

• Lightly lubricate O-rings before installing, this prevents the rings from being pinched when inserting.

Shaft Seals

Before Installation:

Lightly oil the outer circumference, and fill the space between the sealing lips on the outer circumference - arrow - halfway with sealing grease (G 052 128 A1).






After Installation:

• Check the transmission fluid level in the transfer case, refer to => [ Gear Oil Level in the Transfer Case, Checking ] Gear Oil Level In the Transfer Case, Checking.

• Check the transmission fluid level for the front final drive, refer to => [ Axle Oil Level, Checking ] Axle Oil Level, Checking.

• Check the ATF level in rear final drive, refer to => [ Axle Oil Level, Checking ] Axle Oil Level, Checking.

Circlips

• Do not stretch the circlips.

• Always replace damaged or stretched circlips.

• The circlips must touch the bottom of the groove.

Bolts and Nuts

• Loosen and tighten the bolts and nuts of covers and housings in a diagonal sequence.

• Tightening specifications for unlubricated bolts and nuts are given.

• Always replace self-locking nuts and bolts.

• Make sure to wait until after assembly to wax all bolt connections - for example contact surfaces and bolts and nuts - if required.

• Use a wire brush to clean the threads on the bolts that have been screwed in using locking fluid. Install the bolts with locking fluid (AMV 185 101 A1).

• If self-locking bolts were installed or if regular bolts were installed with locking fluid, then the threaded holes must be cleaned with a thread cutter. If the holes are not cleaned, then the bolts could break off the next time they are removed. When cleaning using a thread tap, pay special attention to the thread pitch.

Rubber Mount

• Position the needle bearing with the lettered side (larger metal thickness) facing the thrust piece.