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

Model 166 (except 166.006/058), 292 

Fig 1: Transfer Case Components Location - Model 166 (Except 166.006/058) (Shown On Transfer Case With Code 430)

Courtesy of MERCEDES-BENZ USA

Shown on transfer case with CODE 430 (On & off-road package) 

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	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
	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
	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 self-locking nuts and bolts		AH00.00-N-0001-01A
Notice	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
Notice	General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system		AH00.00-Z-0300-01A
Notice	Notes on battery		AH54.10-P-0001-01A
	Remove/install
1	Perform disable for the high-voltage on-board electrical system	Model 166.063	AR54.10-P-1150GQA
2	Move DIRECT SELECT selector lever to position N
3	Release parking brake
4	Secure vehicle on vehicle lift		AR00.60-P-0100GZ
5	Remove underfloor paneling		AR61.30-P-1001GQ
6	Remove temperature sensor upstream of SCF catalytic converter	Model 166 (except 166.006) with engine 651 with code U42 (Blue TEC diesel exhaust treatment (SCR))	AR14.40-P-2011GZB
7	Remove heat shield (12)	Model 166 (except 166.006/058), 292 with transmission 722.9 with code 430 (On & off-road package)
8	Detach and unclip electrical connections (15a) from transfer case (15)	Model 166 (except 166.006/058), 292 with transmission 722.9 with code 430 (On & off-road package)
9	Unclip wiring harness from transfer case (15)
10	Mark position of rear propeller shaft (6b) relative to output flange
11	Remove rear propeller shaft (6b) at output flange to rear axle from transfer case (15), place to one side and fix in place	Tightening procedure for rear propeller shaft to transfer case	AR41.10-P-0050-17GZ
		Observe tightening procedure for rear propeller shaft (6b).
		Self-locking screw/bolt of propeller shaft at transfer case/adapter housing (to rear axle)	*BA41.10-P-1001-01F
		Retainer wrench	Fig 2
12	Mark position of front propeller shaft (6) relative to output flange
13	Remove front propeller shaft (6a) at output flange to front axle from transfer case (15), place to one side and fix in place	Tightening procedure for front propeller shaft	AR41.10-P-0070-03GZ
		Mark the position of the front propeller shaft (6a) on the output flange.
		Observe tightening procedure for front propeller shaft (6a).
		Self-locking bolt, drive shaft to front axle gear	*BA41.10-P-1004-01F
		Self-locking bolt, drive shaft to transfer case (to front axle)	*BA41.10-P-1003-01F
		Retainer wrench	Fig 2
14	Remove rear engine cross member	Model 292 with engine 642	AR22.10-P-4360OGR
		Model 166 (except 166.006) with engine 651	AR22.10-P-1180GQ
		Model 166 (except 166.058) with engine 276 Model 166 with engine 157 Model 166 with engine 278 Model 166 with engine 642
15	Support rear engine mount using support brace (13)
16	Slowly lower drive train until upper bolts on transfer case (15) are accessible
17	Support transfer case (15) using telescopic lifter and transmission plate (14) and lash down securely
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
	000 588 10 62 00 Support plate		WS26.00-P-3309B
18	Remove bolts from transfer case (15)	Screw/bolt, transfer case to automatic transmission	*BA28.10-P-1002-01A
19	Push transfer case (15) to rear until transfer case (15) is completely detached from transmission (1), and lower transfer case (15)	Move primary shaft of transfer case (15) completely out of transmission (1).
		Apply light coating of grease to gearing on primary shaft of transfer case (15).
		Long-life grease	*BR00.45-Z-1001-06A
20	Install in the reverse order
	Check
21	Check oil filling capacity in transfer case (15) and correct if necessary	Filling screw to transfer case	*BA28.10-P-1001-01A
		Model 166 (except 166.006/058) Double-speed	*BF28.10-P-1001-01E
		Model 166 (except 166.006/058) Single-speed Model 292 Transmission oil
22	Calibrate using diagnostic system, read out fault memory and delete, if necessary
			AD00.00-P-2000-04A
		Menu item: Transfer case (VG)→ Control unit adaptations → Calibration

Fig 2: Identifying Holding Key (164 589 02 07 00)

Courtesy of MERCEDES-BENZ USA