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Stuffing boxes, O-rings transfer case, replacement, B207

Stuffing boxes, O-rings transfer case, replacement, B207

To remove


1. Remove Transfer case, B207 .

2. Secure the transfer case in 78 74 878 Floor stand , use 32 025 053 Holder (EN 47642). Undo the drain plug (A) and drain the oil.


Important

Circlip opening towards "whole" surface.


3. Remove the outer circlip (A) from the housing.


4. Tap out the intermediate shaft (A), use a rubber mallet.


5. Remove circlips (A) and (B).


6. Remove the bearing (C), use tool (D) 87 90 982 Ring, pinion bearing and press off the bearing.


7. Remove the O-ring (A).


8. Remove the transfer case bolts (A), and lift off the housing.


9. Remove the seal (A).


10. Remove the seal (A) and input shaft (B).


11. Remove the O-ring (A) and tube sleeve (B) use tool: 83 90 270 Sliding hammer , 87 92 319 Adapter, 3/8" - M10 and 87 92 939 Puller, bearing in gearcase .


12. Remove the crown wheel (A) and O-ring (B).


13. Remove the seals (A).


14. Remove the dust excluder (A).


15. Remove the seal (B) and the bolts (C).


16. Lift out the pinion's bearing support (A) and shims (B), use a screwdriver against the bottom of the pinion. Remove the O-ring (C).



To fit


1. Remove the sealing compound from the mating face.

2. Fit the O-ring (C), shims (B) and move the pinion's bearing support (A) into position.


3. Fit the bolts (C)

Tightening torque 20 Nm +30 degrees (15 lbf ft +30 degrees)

and stuffing box (B) use tool: DT-49061 Entry cone and DT-49097 Fitting drift .


4. Fit the dust excluder (A), use tool: DT-49095 Fitting drift


5. Fit the seals (A), use tool: DT-49093 Fitting drift .


6. Fit the O-ring (B) and crown wheel (A).


7. Fit the tube sleeve (B) and the O-ring (A).


8. Fit the input shaft's seal (A), use tool: DT-49094 Fitting drift . Fit the input shaft (B).


9. Fit the seal (A), use tool: DT-49093 Fitting drift .


10. Wipe clean the mating face and apply a bead of sealant, Loctite 5970 or equivalent, and lift the housing into place.

11. Fit the transfer case bolts (A), use thread locking adhesive Loctite 243 or equivalent.

Tightening torque 20 Nm +30 degrees (15 lbf ft +30 degrees)


12. Fit the circlip (B), press on the new bearing, use tool: 87 90 982 Ring, pinion bearing and fit the circlip (A).


13. Fit DT-49104 Protective collar , tap in the intermediate shaft (A), use tool: DT-49103 Fitting drift and a rubber mallet. Remove the protection and apply grease to the splines, use Molykote P4 or Mobil XHP 222.


Important

Circlip opening towards "whole" surface.


14. Fit the outer circlip (A) in the housing.


15. Fit the O-ring (A).


16. Fill with 0.65 litres Burmah Castrol SAF PD SAE 75W 85 93 165 383 Transfer case oil in the transfer case.

17. Fit Transfer case, B207 .