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Remove/Install Rear Cover On Transfer Case - AR28.40-P-0815LWX

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MODEL 205, 253 With Transmission 725.0 

with code M005 (Vehicles with 4MATIC/all-wheel drive) 

Fig 1: Rear Cover On Transfer Case Components Location - Model 253 With Transmission 725.0 With Code M005
G14546872DANGERWARNINGCAUTIONCAUTIONREMOVINGINSTALLINGREFER TO MAINTENANCEREFER TO SHOP-MADE TOOLSTORQUE SPECIFICATIONSPECIAL TOOLINSTALLATION IMPORTANTTORQUE SPECIFICATIONINSTALLATION IMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONINSTALLATION IMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONSPECIAL TOOLSPECIAL TOOLSPECIAL TOOLINSTALLATION IMPORTANTTORQUE SPECIFICATIONWARNINGCourtesy of MERCEDES-BENZ USA
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
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
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
Notice Notes on threaded connections fastened using a tightening angle-based tightening process   AH00.00-P-0020-01A
Notice Notes on self-locking nuts and bolts   AH00.00-P-0001-01KOA
Notice Notes on threaded connections with aluminum screws/bolts   AH00.00-P-0006-01RM
REMOVINGINSTALLING Remove/install     
1 Put transmission into neutral position.    
2 Release parking brake.    
3 Secure vehicle on vehicle lift.   AR00.60-P-0100CW
4 Remove center and rear section of lower engine compartment paneling.   AR61.20-P-1105LW
5 Drain transmission oil from transfer case.    
REFER TO MAINTENANCE   Transmission 725.0 (except 725.06/09) in model 205, 253 with code M005 (Vehicles with 4MATIC/all-wheel drive) AP28.00-P-2801A 
6 Remove heat shield behind transmission and slide backward.    
7 Detach propeller shaft from output flange (2) of transfer case, slide backward and shim. Transmission 725.0 in model 205 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR41.10-P-0040-01LW
    Transmission 725.0 in model 253 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR41.10-P-0041-01LW
REFER TO SHOP-MADE TOOLS Drift for releasing the fitting sleeves in the flexible couplings   WF58.50-P-4110-01A
    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. Transmission 725.0 in model 205 with engine 177 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR22.10-P-1160MNA
    Transmission 725.0 in model 253 with engine 177 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR22.10-P-1160MNG
    Transmission 725.0 in model 205 with engine 264 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 205, 253 with engine 274 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 205, 253 with engine 276.8 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 205, 253 with engine 651 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 205, 253 with engine 654 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 253 with engine 642 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 253 with engine 656 with code M005 (Vehicles with 4MATIC/all-wheel drive)		 AR22.10-P-1160LWB
9.1 Remove clamp securing front exhaust system to right and left catalytic converter. Transmission 725.0 in model 205, 253 with engine 276.8 with code M005 (Vehicles with 4MATIC/all-wheel drive)
INSTALLATION IMPORTANT : Replace the clamp securing the front exhaust system and the seal.		  
    TORQUE SPECIFICATION Transmission 725.0 in model 205, 253 with engine 276.8 with code M005 (Vehicles with 4MATIC/all-wheel drive) Clamp, front exhaust system to catalytic converter/diesel particulate filter *BA49.10-P-1005-02A 
9.2 Remove clamp securing front exhaust system to right catalytic converter. Transmission 725.0 in model 205 with engine 264 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 205, 253 with engine 274 with code M005 (Vehicles with 4MATIC/all-wheel drive)
INSTALLATION IMPORTANT : Replace the clamp securing the front exhaust system and the seal.		  
    TORQUE SPECIFICATION Transmission 725.0 in model 205 with engine 264 with code M005 (Vehicles with 4MATIC/all-wheel drive) Clamp at catalytic converter and front exhaust system *BA49.10-P-1002-02P 
    TORQUE SPECIFICATION Transmission 725.0 in model 205, 253 with engine 274 with code M005 (Vehicles with 4MATIC/all-wheel drive) Clamp, front exhaust system to catalytic converter/diesel particulate filter *BA49.10-P-1005-02A 
9.3 Remove front exhaust system clamp from diesel particulate filter. Transmission 725.0 in model 205, 253 with engine 651 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 205, 253 with engine 654 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 253 with engine 642 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 253 with engine 656 with code M005 (Vehicles with 4MATIC/all-wheel drive)
INSTALLATION IMPORTANT : Replace the clamp securing the front exhaust system and the seal.		  
    TORQUE SPECIFICATION Transmission 725.0 in model 205, 253 with engine 651 with code M005 (Vehicles with 4MATIC/all-wheel drive) Clamp, front exhaust system to catalytic converter/diesel particulate filter *BA49.10-P-1005-02A 
    TORQUE SPECIFICATION Transmission 725.0 in model 253 with engine 642 with code M005 (Vehicles with 4MATIC/all-wheel drive) Clamp to diesel particulate filter and front exhaust system *BA49.10-P-1003-02K 
    TORQUE SPECIFICATION Transmission 725.0 in model 205, 253 with engine 654 with code M005 (Vehicles with 4MATIC/all-wheel drive) Clamp to diesel particulate filter and front exhaust system *BA49.10-P-1003-02H 
    TORQUE SPECIFICATION Transmission 725.0 in model 253 with engine 656 with code M005 (Vehicles with 4MATIC/all-wheel drive) Clamp to diesel particulate filter and front exhaust system *BA49.10-P-1001-02O 
10 Lower transmission until all screws (1) on cap (3) are accessible.    
11 Remove output flange (2) from transmission.   AR28.10-P-4080-02A 
    TORQUE SPECIFICATION Nut, output flange to transfer case *BA28.10-P-1006-01G 
    SPECIAL TOOL Socket wrench bit Fig 5
    SPECIAL TOOL Puller, two-arm Fig 4
    SPECIAL TOOL Pin wrench Fig 3
12 Remove radial shaft sealing ring from output flange (2).   AR28.10-P-4150LWX 
13 Remove screws (1) and take off cap (3).    
  Notes on sealing the transfer case INSTALLATION IMPORTANT : Observe sealant path. AH28.10-P-0100-01AVG 
    TORQUE SPECIFICATION Bolt, rear transfer case cover to transfer case *BA28.10-P-1005-01G 
14 Install in the reverse order.    
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
15 Perform engine test run and check transfer case for proper operation and leak tightness.    
COMPLETE TRANSFER CASE

Number Designation Model 205, 206, 213, 217, 218, 222, 223, 238, 253, 257, 290 with transmission 725.0/1 with code M005 (Vehicles with 4MATIC/all-wheel drive)
BA28.10-P-1005-01G Bolt, rear transfer case cover to transfer case Nm 40
COMPLETE TRANSFER CASE

Number Designation Model 205, 206, 213, 217, 218, 222, 223, 238, 253, 257, 290 with transmission 725.0/1 with code M005 (Vehicles with 4MATIC/all-wheel drive)
BA28.10-P-1006-01G Nut, output flange to transfer case Nm 200
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 253 with engine 656
BA49.10-P-1001-02O Clamp to diesel particulate filter and front exhaust system Nm 14
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 Model 253 with engine 654
BA49.10-P-1003-02H Clamp to diesel particulate filter and front exhaust system Nm 14 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
Fig 2: Identifying Counterholder (176 589 00 40 00)
G14546873Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Pin Wrench (129 589 01 07 00)
G14546874Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Puller, Two-Arm (000 589 88 33 00)
G14546875Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Socket Wrench Bit (126 589 02 09 00)
G14546876Courtesy of MERCEDES-BENZ USA
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