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Transfer case, B207

Transfer case, B207

To remove


1. Raise the car.

2. Aut: Drain the fluid through the level pipe.

Man: Drain the gearbox of oil.

3. Remove Subframe, B207, 4WD .

4. Remove the head shield (A) and the lower turbocharger delivery pipe (B).


Warning

Use protective goggles to protect against flying splinters of metal.


5. Tap the drive shaft out from the intermediate shaft, use a brass drift and mallet (C). Move the drive shaft aside.


6. Remove the rear torque rod (A).


7. Remove the rear torque rod bracket (A).


8. Remove the support bracket (B) from the transfer case.


9. Support the transfer case with a column jack, and secure with cable ties.


10. Remove the transfer case bolts (C) using DT-48783 Special socket .

Important

Be careful that the servo pipe does not get damaged.



11. Lower and ease out the transfer case.


To fit


1. Clean the contact surfaces between the transfer case and the gearbox. Fit a new O-ring (A).


2. Raise and align the transfer case in the correct position in relation to the gearbox.

3. Fit the transfer case (A). Tighten the bolts in the correct order as illustrated.

Tightening torque 110 Nm (81 lbf ft).


4. Fit the support bracket between the transfer case and the engine carefully in three steps to avoid breakage.

Tightening torque, bolts (B) step 1: 5 Nm (3.7 lbf ft)


Tightening torque, bolts (C) step 2: 60 Nm (44 lbf ft)

Tightening torque, bolts (B) step 3: 60 Nm (44 lbf ft).

5. Fit the rear torque rod bracket (A).

Tightening torque 80 Nm (59 lbf ft)


6. Fit the rear torque rod. Tighten the bolt (A) loosely.


7. Fit the drive shaft in the intermediate shaft splines. Lubricate the shaft splines using 90 513 210 Universal paste . Make sure that the seal to the intermediate shaft is fitted.

8. Fit the lower turbocharger delivery pipe (B) and the heat shield (A).


9. Fit Subframe, B207, 4WD .

10. Tighten the rear torque rod (A) to the torque rod bracket.

Tightening torque 60 Nm +90° (44 lbf ft +90°)


11. Check the oil level in the transfer case as specified in Transfer case, checking/filling oil .

12. Aut: Top up fluid as specified in Checking/adjusting the fluid level

Man: Fill with oil as specified in Filling/changing gearbox oil .