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Transfer case, B207

Transfer case, B207

To remove


1. Raise the car.

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

Man: Drain the oil from the gearbox.

3. Remove Subframe, B207, 4WD .

4. Remove the heat shield (A) and lower turbo pressure pipe (B).


Warning

Use protective goggles to protect against flying splinters of metal.


5. Knock the drive shaft out of the intermediate shaft, use a brass drift and mallet (C). Put the drive shaft to one side.


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 a strap.


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

Important

Be careful that the servo pipe does not get damaged.



11. Lower the transfer case and work it out gently.


To fit


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


2. Raise the transfer case and position it correctly to the gearbox.

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

Tightening torque 110 Nm (81 lbf ft).


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

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


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

Tightening torque bolts (B) stage 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 turbo pressure pipe (B) and 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 transfer case according Transfer case, checking/filling oil .

12. Aut: Fill fluid in accordance with Checking/adjustment of fluid level

Man: Fill oil in accordance with Filling/changing the gearbox oil .