Mercedes-Benz Cars 2000-05

Transfer Case Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the fluid and remove the exhaust brackets. Suspend the exhaust with a piece of wire.
  4.  
  5. Remove or disconnect the following:

    Driveshaft shield
     
    Case bracket
     
    Case vibration damper
     
    Front half of rear driveshaft
     

  6.  
  7. Support the transmission and remove the engine support along with the rear engine mount. Lower the assembly slightly.

    Front driveshaft
     
    Transfer case bolts
     
    Transfer case and drain the residual oil
     

  8.  

To install:

  1. Install or connect the following:

    Transfer case with new gasket. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    Rear engine support. Torque the bolts to 30 ft. lbs. (40 Nm).
     
    Driveshafts. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Case vibration damper
     
    Driveshaft shield
     
    Exhaust brackets
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the fluid and remove the exhaust brackets. Suspend the exhaust with a piece of wire.
  4.  
  5. Remove or disconnect the following:

    Front half of rear driveshaft
     
    Front driveshaft
     
    Servomotor connector
     

  6.  
  7. Support the transmission and remove the engine support along with the rear engine mount. Lower the assembly slightly.
  8.  
  9. Remove or disconnect the following:

    Transfer case bolts
     

  10.  
  11. Remove the transfer case and drain the residual oil.
  12.  


    Click image to see an enlarged view

    Fig. Exploded view of the components associated with transfer case removal and installation


To install:

  1. Install or connect the following:

    Transfer case with new gasket. Torque the bolts to 15 ft. lbs. (20 Nm)
     
    Rear engine support. Torque the bolts to 30 ft. lbs. (40 Nm)
     
    Front driveshaft. Torque the bolts to 37 ft. lbs. (50 Nm)
     
    Front half of rear driveshaft. Torque the bolts to 30 ft. lbs. (40 Nm)
     
    Servomotor connector
     
    Exhaust brackets
     

  2.  
  3. Fill the transfer case with fluid.
  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the fluid and remove the exhaust brackets. Suspend the exhaust with a piece of wire.
  4.  
  5. Remove or disconnect the following:

    Driveshaft shield
     
    Case bracket
     
    Case vibration damper
     
    Front half of rear driveshaft
     

  6.  
  7. Support the transmission and remove the engine support along with the rear engine mount. Lower the assembly slightly.
  8.  
  9. Remove or disconnect the following:

    Front driveshaft
     
    Transfer case bolts
     

  10.  
  11. Remove the transfer case and drain the residual oil.
  12.  

To install:

  1. Install or connect the following:

    Transfer case with new gasket. Torque the bolts to 22 ft. lbs. (30 Nm)
     
    Rear engine support. Torque the bolts to 30 ft. lbs. (40 Nm)
     
    Driveshafts. Torque the bolts to 18 ft. lbs. (25 Nm)
     
    Case vibration damper
     
    Driveshaft shield
     
    Exhaust brackets
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the fluid and remove the exhaust brackets. Suspend the exhaust with a piece of wire.
  4.  
  5. Remove or disconnect the following:

    Driveshaft shield
     
    Case bracket
     
    Case vibration damper
     
    Front half of rear driveshaft
     

  6.  
  7. Support the transmission and remove the engine support along with the rear engine mount. Lower the assembly slightly.
  8.  
  9. Remove or disconnect the following:

    Front driveshaft
     
    Transfer case bolts
     

  10.  
  11. Remove the transfer case and drain the residual oil.
  12.  

To install:

  1. Install or connect the following:

    Transfer case with new gasket. Torque the bolts to 22 ft. lbs. (30 Nm)
     
    Rear engine support. Torque the bolts to 30 ft. lbs. (40 Nm)
     
    Driveshafts. Torque the bolts to 18 ft. lbs. (25 Nm)
     
    Case vibration damper
     
    Driveshaft shield
     
    Exhaust brackets
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the fluid and remove the exhaust brackets. Suspend the exhaust with a piece of wire.
  4.  
  5. Remove or disconnect the following:

    Driveshaft shield
     
    Case bracket
     
    Case vibration damper
     
    Front half of rear driveshaft
     

  6.  
  7. Support the transmission and remove the engine support along with the rear engine mount. Lower the assembly slightly.

    Front driveshaft
     
    Transfer case bolts
     
    Transfer case and drain the residual oil
     

  8.  

To install:

  1. Install or connect the following:

    Transfer case with new gasket. Torque the bolts to 18 ft. lbs. (25 Nm)
     
    Rear engine support. Torque the bolts to 30 ft. lbs. (40 Nm)
     
    Driveshafts. Torque the bolts to 18 ft. lbs. (25 Nm)
     
    Case vibration damper
     
    Driveshaft shield
     
    Exhaust brackets
     

  2.  

On 4MATIC models, a -transfer case- assembly is located on the end of the transmission and is used to transmit torque to the front drive axles.

 
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