Remove/install transfer case - AR28.10-P-0100I

MODEL 220.083 /084 /087 /183 /184 /187

Fig 1: Identifying Transfer Case Remove/Install Components

Fig 2: Locating Automatic Transmission

MODIFICATION NOTES

31.1.06

Transmission oil, Specifications for Operating Fluids

*BF28.10-P-1001-01D

	Remove
1	Open engine hood		AR88.40-P-1000M
2	Remove hot film mass air flow sensor		AR07.07-P-1454AA
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
3	Raise vehicle with lifting platform
4	Detach lower engine compartment paneling		AR61.20-P-1105M
5	Detach exhaust shielding plate (41) for front propeller shaft behind the transfer case (16)
6	Remove exhaust bracket (44)
7	Detach transmission ground (W49) from transfer case (16).
8	Remove right O2 sensor downstream of TWC [KAT] (G3/6)		AR14.00-P-5303AA
9	Mark propeller shaft (70) of front axle gear relative to flange of transfer case (16)
10	Detach propeller shaft (70) of front axle gear on transfer case (16)
11	Detach front propeller shaft from flange on transfer case (16)	The flexible coupling remains on the propeller shaft.
12	Loosen fitted sleeves of flexible coupling and push back propeller shaft	If the fitted sleeves are jammed: ↓	AR41.10-P-0050-09I
		Prepare drift for loosening fitted sleeves in flexible couplings.	WF58.50-P-4110-01A
13	Unhook shift rod (50) at automatic transmission (17)	To unhook, press the locking device (50a) upwards until the bolt of the shift rod (50) can be moved out.
14	Dismount reinforcement bridge (49)
15	Unhook rear exhaust system (48) from the exhaust rubber mounts, lower slightly and tie securely
16	Support k automatic transmission (17) with transmission jack and transmission platform	Transmission platform	*WE58.40-Z-1018-11A
		Telescoping / transmission jack	*WE58.40-Z-1030-11A
17	Remove rear engine crossmember (42)	See: ↓
		Remove rear engine mount.	AR22.10-P-1160IW
18	Slightly lower automatic transmission (17)
19	Detach transfer case (16) from automatic transmission (17)	Four nuts and seven bolts
	Install
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
20	Coat plug-type splines in transfer case (16) with grease	Klueber Microlube GNY 202	*BR00.45-Z-1071-06A
21	Mount transfer case (16) to automatic transmission (17)	Both centering sleeves (arrows) have to be firmly seated in the automatic transmission (17), if necessary replace centering sleeves. Four nuts and seven bolts
			*BA28.10-P-1001-01C
22	Check oil level in transfer case (16), correct if necessary		AR28.10-P-1000-26I
		Transmission platform	*WE58.40-Z-1018-11A
		Telescoping / transmission jack	*WE58.40-Z-1030-11A
		Transfer case filling capacity	*BF28.10-P-1001-01D
		Oil filler opening screw plug	*BA28.10-P-1004-01C
		Inspection hole screw plug	*BA28.10-P-1005-01C
23	Install rear engine crossmember (42)	See: ↓
		Install rear engine mount.	AR22.10-P-1160IW
24	Remove transmission jack and transmission platform	Transmission platform	*WE58.40-Z-1018-11A
		Telescoping / transmission jack	*WE58.40-Z-1030-11A
25	Attach rear exhaust system (48) to the exhaust rubber mounts
26	Attach stiffening bridge (49)		*BA61.10-P-1002-01D
27	Attach front propeller shaft to flange of transfer case (16)		AR41.10-P-0050-07I
			*BA41.10-P-1001-01A
28	Attach transmission ground (W49) at transfer case (16)
29	Attach exhaust shielding plate (41) for front propeller shaft behind transfer case (16).
30	Mount exhaust bracket (44)	Check tapping plates (44a), replace if necessary.
31	Install right O2 sensor downstream of TWC [KAT] (G3/6)		AR14.00-P-5303AA
32	Attach propeller shaft (70) of front axle gear to flange of transfer case (16)	Observe marking.
			*BA33.30-P-1005-02C
33	Hook in shift rod (50) on automatic transmission (17)
34	Install lower engine compartment paneling		AR61.20-P-1105M
35	Install hot film mass air flow sensor		AR07.07-P-1454AA
36	Close engine hood		AR88.40-P-1000M

TRANSFER CASE COMPLETE

Number	Designation		Model 220.08/18 except model 220.087/187	Model 220.087/187
BA28.10-P-1001-01C	Nut and bolt, transfer case to automatic transmission	Nm	25	25
BA28.10-P-1004-01C	Oil filler opening screw plug	Nm	30	30
BA28.10-P-1005-01C	Inspection hole screw plug	Nm	30	30

FRONT AXLE SHAFT

Number	Designation				Model 220.08/18
BA33.30-P-1005-02C	Bolt of front axle gear propeller shaft to transfer case flange	M8	Stage 1	Nm	15
			Stage 2	∠°	30
		M10	Stage 1	Nm	-
			Stage 2	∠°	-

PROPELLER SHAFT

Number	Designation			Model 220
BA41.10-P-1001-01A	Self-locking nut of flexible joint to transmission or front propeller shaft	M10	Nm	-
BA41.10-P-1001-01A		M12	Nm	60

FRAME FLOOR ASSEMBLY

Number	Designation		Model 220
BA61.10-P-1002-01D	Collar bolt of rear reinforcement bridge to frame floor	Nm	23

TRANSFER CASE COMPLETE

Number	Designation			Model 220.083/084/ 087/183/184/187
BF28.10-P-1001-01D	Gear oil	Filling capacity	Liters	0.59
BF28.10-P-1001-01D	Gear oil	Specifications for Operating Fluids	Sheet	BB00.40-P-0236-13A

WORKSHOP EQUIPMENT

WE58.40-Z-1018-11A	Transmission platform
WE58.40-Z-1030-11A	Transmission jack

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1071-06A	Klueber Microlube GNY 202	A 001 989 44 51 10