327 Mod 07 W463 T-case _DC_ 03-02-04

Allen 5, 6mm. • Snap ring pliers - small. • Screwdriver #2. • Hammer – ... Depth of the bearing seat ______. Distance to the outer race ______. Shim thickness.
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Module Number: 07 Subject: G-class Transfer case

Objective: At the conclusion of this module you will be able to: • Disassemble and assemble transfer case • Calculate shim thickness required for axial play adjustment • Explain the operation of the transfer case. Vehicle and tools required: • • • • • • • • • •

Transfer case 750.654, input shaft flanges removed Vernier caliper and depth gauge Torque wrench (10-40Nm) Sockets 13, 22mm Ratchet and extension Allen 5, 6mm Snap ring pliers - small Screwdriver #2 Hammer – plastic MB Special Tools

Required material: •

N/A

Instructions: 1. Follow the instructions and answer the questions. 2. Ask your instructor if assistance is needed. 3. Stop at Instructor checkpoints for sign-off. 327 Mod 07 W463 T-case (DC) 03-02-04

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1 2 3 4

Coupling flange Closing cover Shift fork Cylindrical actuator housing

5 6 7 8

Diaphragm Shift mechanism of differential lock Front transmission cover Transmission housing

9 Intermediate flange 10 Cover of rear axle input shaft 11 Cover of intermediate flange 12 Drive shaft

13 14 M46/2

Countershaft Differential Transfer case actuator motor

1. Remove transfer case actuator motor. Note location of ground cable. Motor must be Initialized when it is reinstalled. 2. Remove intermediate flange cover. Note bolt size and location. Note shims for input and counter shafts. 3. Remove snap ring and washer on the high/low shifter shaft bearing. 4. Remove in intermediate flange. 5. Remove differential. (AR28.50-P-1023GM) 327 Mod 07 W463 T-case (DC) 03-02-04

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6. Remove input and counter shaft. (AR28.50-P-1019GM) 7. Remove high/low shift fork. Note the small barrel bushing. 8. Assemble transfer case in reverse order. 9. “Check and adjust axial play of input shaft and countershaft” (AR28.50-P-1018-02B) 10. What is the specification for “Preload of tapered roller bearing of countershaft and input shaft”? _______________mm 11. Calculate the shim thickness for the countershaft. Depth of the bearing seat _____________ Distance to the outer race _____________ Shim thickness _____________ 12. Calculate the shim thickness for the input shaft. Depth of the bearing seat _____________ Distance to the outer race _____________ Shim thickness _____________

327 Mod 07 W463 T-case (DC) 03-02-04

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