Disassembling And Assembling Rear Differential Lock Shift Cylinder - AR35.40-P-9135F

Model 460 

Model 461 (except 461. 331) 

Model 463 (except 463.270/271) 

up to model year 2013 

Courtesy of MERCEDES-BENZ USA

	Remove
	Risk of poisoning  from swallowing brake fluid. Risk of injury  from skin and eye contact with brake fluid	Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.	AS42.50-Z-0001-01A
	Brake fluid notes		AH42.50-P-0001-01A
1	Remove shift cylinder on differential lock		AR35.40-P-9131F
	Disassemble/assemble
2	Unscrew pressure switch (1)	Assembly:  Only tighten pressure switch (1) to 1st stage.
		Pressure switch to shift cylinder	*BA35.40-P-1005-01A
		Socket wrench bit	Fig 1
3	Detach cap (14)	Undo bolts (15) from cover (14), spring loaded.
		Assembly:  Install new seal (13).
		Bolt, cover to shift cylinder	*BA35.40-P-1002-01A
4	Remove piston (12) and push spring (9)	Assembly:  Replace dust boot (10) and seal boot (11), observe installation position. Coat dust boot (10), seal boot (11) and piston (12) with MB silicone grease.
		ABS sensor grease	*BR00.45-Z-1019-06A
5	Unscrew shift shaft (5) from shifter lever (3)	Assembly:  Apply quick-action adhesive to the thread of the shift shaft (5).
		Shift shaft to gearshift lever for cross-axle differential lock	*BA35.40-P-1003-01A
		Quick-acting adhesive, Loctite 270	*BR00.45-Z-1008-02A
6	Remove gearshift lever (3) and shift shaft (5) with switch spring (4) from the shift cylinder housing (2)
7	Disassemble shift shaft (5)	To facilitate dismantling of the separate parts screw the gearshift lever (3) onto the shift shaft (5) and clamp in vise.
		Assembly:  Circlip (8) must engage in the groove. To facilitate assembly of separate parts screw the gearshift lever (3) onto the shift shaft (5) and clamp in vise.
		Clamping device	Fig 2
	Clean
8	Clean all parts	Cold degreasing agent/cold cleaning solvent HAKU 1025-920	*BR00.45-Z-1051-04A
	Check
9	Check all parts for wear and damage, replace if necessary
10	Assemble in the reverse order
	Install
11	Install shift cylinder for differential lock		AR35.40-P-9131F
12	Tighten pressure switch (1)	Tighten pressure switch (1) with the 2nd stage.
		Pressure switch to shift cylinder	*BA35.40-P-1005-01A

Fig 1: Identifying Socket Wrench Bit (620 589 01 09 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Clamping Device (381 589 00 31 00)

Courtesy of MERCEDES-BENZ USA