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Remove/Install Transfer Case - AR28.10-P-0100LWX

Transmission 725.0 (except 725.09) in model 205, 253 with code M005 (4MATIC) 

MODIFICATION NOTES

03.12.2018 "Basic date ", added. Operation step 9.2 BA49.10-P-1002-02P

Shown on model 253 

G12935879Courtesy of MERCEDES-BENZ USA
G12935880Courtesy of MERCEDES-BENZ USA
G12935881Courtesy of MERCEDES-BENZ USA
CAUTION Risk of injury  to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.		 AS00.40-Z-0001-01A
CAUTION Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. AS00.00-Z-0017-01A
WARNING Risk of injury.  Skin or eye injuries may result when handling hot or glowing objects. Wear protective gloves, protective clothing and safety glasses, if necessary. AS00.00-Z-0002-01A
  Notes on bolted connections with self tapping screws   AH00.00-P-0007-01SF
  Notes on threaded connections fastened using a tightening angle-based tightening process   AH00.00-P-0020-01A
  Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
  Notes on threaded connections with aluminum screws/bolts   AH00.00-P-0006-01RM
  Notes on automatic transmission   AH27.19-P-0001-01NKB
REMOVINGINSTALLING Remove/install     
1 Shift the transmission (5) into neutral position.    
2 Secure vehicle to prevent it moving away.    
3 Release parking brake.    
4 Secure vehicle on vehicle lift.   AR00.60-P-0100CW
5 Remove center and rear lower engine compartment lining. INSTALLATION IMPORTANT Install center and rear lower engine compartment lining after the leak test. AR61.20-P-1105LW
6 Remove heat shield behind transmission (5) and slide backward. Transmission 725.0 (except 725.09) in model 205
with code M005 (4MATIC)		  
7 Remove propeller shaft (3) from output flange of transfer case (7), slide backward and secure against falling down. Transmission 725.0 (except 725.09) in model 205
with code M005 (4MATIC)		 AR41.10-P-0040-01LW
    Transmission 725.0 (except 725.09) in model 253
with code M005 (4MATIC)		 AR41.10-P-0041-01LW
REFER TO SHOP-MADE TOOLS Drift for releasing the fitting sleeves in the   WF58.50-P-4110-01A
  flexible couplings TORQUE SPECIFICATION Flex disk or joint flange at transmission/rear axle differential or propeller shaft *BA41.10-P-1001-01L 
    SPECIAL TOOL Counterholder Fig 2
8 Remove rear engine mount (2). Transmission 725.0 (except 725.09) in model 205 with engine 264, 274, 276.8, 651, 654 with code M005 (4MATIC), transmission 725.0 (except 725.09) in model 253 with engine 274, 276.8, 642, 651 with code M005 (4MATIC)  
      AR22.10-P-1160LWB
9.1 Remove clamps securing front exhaust system to right and left catalytic converter. Transmission 725.0 (except 725.09) in model 205, 253 with engine 276.8 with code M005 (4MATIC)
INSTALLATION IMPORTANT Replace the clamps securing the front exhaust system and the seal.		  
    TORQUE SPECIFICATION Clamp, front exhaust system to catalytic converter/diesel particulate filter *BA49.10-P-1005-02A 
9.2 Remove clamp securing front exhaust system to catalytic converter. Transmission 725.0 (except 725.09) in model 205 with engine 264
with code M005 (4MATIC)
Transmission 725.0 (except 725.09) in model 205, 253 with engine 274 with code M005 (4MATIC)
INSTALLATION IMPORTANT Replace the clamp securing the front exhaust system and the seal.		  
    TORQUE SPECIFICATION Transmission 725.0 (except 725.09) in model 205 with engine 264
with code M005 (4MATIC) Clamp at catalytic converter and front exhaust system		 BA49.10-P-1002-02P
    TORQUE SPECIFICATION Transmission 725.0 (except 725.09) in model 205, 253 with engine 274
with code M005 (4MATIC) Clamp, front exhaust system to catalytic converter/diesel particulate filter		 *BA49.10-P-1005-02A 
9.3 Remove clamp securing front exhaust system to diesel particulate filter. Transmission 725.0 (except 725.09) in model 205, 253 with engine 651
with code M005 (4MATIC)
Transmission 725.0 (except 725.09) in model 253 with engine 642
with code M005 (4MATIC)
Transmission 725.0 in model 205 with engine 654
with code M005 (4MATIC)
INSTALLATION IMPORTANT Replace the clamp securing the front exhaust system and the seal.		  
    TORQUE SPECIFICATION Transmission 725.0 (except 725.09) in model 205, 253 with engine 651 with code M005 (4MATIC) Clamp, front exhaust system to catalytic converter/diesel particulate filter BA49.10-P-1005-02A
    TORQUE SPECIFICATION Transmission 725.0 (except 725.09) in model 253 with engine 642
with code M005 (4MATIC) Clamp to diesel particulate filter and front exhaust system		 BA49.10-P-1003-02K
    TORQUE SPECIFICATION Transmission 725.0 in model 205 with engine 654
with code M005 (4MATIC) Clamp to diesel particulate filter and front exhaust system		 BA49.10-P-1003-02H
10 Lower transmission (5) until all screws (6) around the circumference of the transfer case (7) are accessible.    
11 Support transfer case (7).    
REFER TO SPECIAL TOOLS 000 588 10 62 00 Support plate   WS26.00-P-3309B
REFER TO SPECIAL TOOLS 000 588 11 62 00 Major assembly mount   WS01.00-P-0092B
12 Unscrew screws (6) and remove transfer case (7). INSTALLATION IMPORTANT Before mounting the transfer case (7) coat the gearing of the transmission's output shaft (5) with grease.
IMPORTANT The aid of a second person is required for disconnection and connection at the flange of the front axle propeller shaft (4).		  
    Klueber Microlube GNY 202 *BR00.45-Z-1071-06A 
    TORQUE SPECIFICATION Bolt, transfer case to automatic transmission *BA28.10-P-1001-01G 
13 Check intermediate panel (8) for damage. If damage is found,
↓
Replace intermediate panel (8).		  
14 Install in the reverse order.    
15 Check and correct oil level of transfer case (7). Transmission 725.0 (except 725.06/09) in model 205, 253
with code M005 (4MATIC)		 AR28.10-P-0100-06A 
    Assembly cleaner *BR00.45-Z-1028-04A 
    FLUID SPECIFICATION Transfer case oil *BF28.10-P-1001-01F 
    TORQUE SPECIFICATION Drain screw to transfer case *BA28.10-P-1003-01G 
    TORQUE SPECIFICATION Oil level sight glass to transfer case *BA28.10-P-1007-01G 
    SPECIAL TOOL Hand pump Fig 1
WARNING Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running. Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
16 Perform engine test run and check transfer case (7) for proper operation and leak tightness    
17 Install center and rear lower engine compartment lining.   AR61.20-P-1105LW
COMPLETE TRANSFER CASE

Number Designation Model 205, 213, 217, 218, 222, 238, 253, 257, 290 with transmission 725.0 with code M005 (4MATIC)
BA28.10-P-1001-01G Bolt, transfer case to automatic transmission Stage 1 Nm 30
Stage 2 ∠° 90
COMPLETE TRANSFER CASE

Number Designation Model 205, 213, 217, 218, 222, 238, 253, 257, 290 with transmission 725.0 with code M005 (4MATIC)
BA28.10-P-1003-01G Drain screw to transfer case Nm 25
COMPLETE TRANSFER CASE

Number Designation Model 205, 213, 217, 218, 222, 238, 253, 257, 290 with transmission 725.0 with code M005 (4MATIC)
BA28.10-P-1007-01G Oil level sight glass to transfer case Nm 11
PROPELLER SHAFT

Number Designation Model 205 Model 253
BA41.10-P-1001-01L Flex disk or joint flange at transmission/rear axle differential or propeller shaft Self-locking nut   Nm 68  
Direct threaded connection Stage 1 Nm 60 60
Stage 2 ∠° 90 90
EXHAUST SYSTEM

Number Designation Model 205 with engine 264
BA49.10-P-1002-02P Clamp at catalytic converter and front exhaust system Nm 25
EXHAUST SYSTEM

Number Designation Model 205 with engine 654
BA49.10-P-1003-02H Clamp to diesel particulate filter and front exhaust system Nm 14
EXHAUST SYSTEM

Number Designation Model 253 with engine 642
BA49.10-P-1003-02K Clamp to diesel particulate filter and front exhaust system Nm 14
EXHAUST SYSTEM

Number Designation Engine 274 in model 205 Engine 274 in model 253
BA49.10-P-1005-02A Clamp, front exhaust system to catalytic converter/diesel particulate filter Nm 22 22
EXHAUST SYSTEM

Number Designation Engine 276 in model 205 Engine 276 in model 253
BA49.10-P-1005-02A Clamp, front exhaust system to catalytic converter/diesel particulate filter Nm 19 19
EXHAUST SYSTEM

Number Designation Engine 651 in model 205 Engine 651 in model 253
BA49.10-P-1005-02A Clamp, front exhaust system to catalytic converter/diesel particulate filter Nm 14 14
COMPLETE TRANSFER CASE

Number Designation Model 167, 205, 213, 217, 218, 222, 238, 253, 257, 290 with transmission 725.0
BF28.10-P-1001-01F Transfer case oil Filling capacity Liter 0, 5
Specification sheet   BB00.40-P-0236-15A
Fig 1: Identifying Hand Pump (210 589 00 71 00)
G12935882Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Counterholder (176 589 00 40 00)
G12935883Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
BR00.45-Z-1071-06A Klueber Microlube GNY 202 A 001 989 44 51 10
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