Transfer Case: Service and Repair
WM 396519 Removing and installing transfer gear
Technical values
Preliminary work for transfer gear
1. Remove engine guard. => 108019 Removing and installing engine guard - section on "Removing"
2. Remove rear cardan shaft. => 393519 Removing and installing rear cardan shaft - section on "Removing"
Removing transfer gear
Overview of removing and installing transfer box
Information
- To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by actuating the foot brake.
1. Remove front cardan shaft on the transfer box and tie it up.
Front cardan shaft to transfer box
2. Remove heat protection from cable plugs on servo motor.
Heat protection on servo motor for transfer box
Information
- The temperature sensor -1- on the transfer box is no longer used in model year 2004.
- If there is no temperature sensor, secure cable plug on the servo motor with tie-wraps.
Plug sequence for transfer box servo motor
3. Pull off cable plug on the servo motor -1 , 2- and release cable holder.
Cable plug on servo motor
Information
Always observe the exact work sequence when installing/removing the transmission cross member.
4. Remove transmission cross member.
5. Support transmission with transmission jack and secure with retaining band.
6. Unscrew bolts on body -A-.
Transmission cross member
7. Unscrew two transmission cross member screws -B- on transfer box holder.
8. Place a wooden block -arrow- between the converter bell housing and suspension subframe.
Supporting transmission
9. Unscrew fastening nut and push holder with Tiptronic line -A- away to the side.
Tiptronic line holder
10. Unscrew fastening screws -arrows- securing transfer box to main transmission.
Transfer box to main transmission
11. Separate transfer box from main transmission.
Removing transfer box
12. Gradually drain transfer box. Pull out vent line and remove it from the retainers -arrows- on the upper side.
Vent line support
Installing transfer gear
1. Support main transmission on converter bell housing with a wooden block -arrow-.
Supporting transmission
2. Gradually run in transfer box. Press vent line into holder -arrow- and attach to transfer box.
Vent line support
3. Tighten fastening screws on main transmission. => Tightening torque: 45 Nm (33 ftlb.)
Transfer box to main transmission
4. Tighten support -A- for Tiptronic line using fastening nut -arrow-. => Tightening torque: 10 Nm (7.5 ftlb.)
Transfer box
5. Support transfer box with transmission jack and remove wooden block between converter bell housing and suspension subframe.
Supporting transmission
Information
Always observe the exact work sequence when installing/removing the transmission cross member.
Information
- Screws which are tightened with a torque angle must be replaced with new ones.
6. Install transmission cross member.
7. Screw in two cross member screws -B- on transfer box support. => Initial tightening: 50 Nm (37 ftlb.) => Final tightening: 90° (67 ftlb.)
Transmission cross member
8. Screw in fastening screws for securing transmission cross member to body -A-. => Initial tightening: 50 Nm (37 ftlb.) => Final tightening: 90° (67 ftlb.)
Information
- Screws which are tightened with a torque angle must be replaced with new ones.
9. Connect front cardan shaft to transfer box. => Initial tightening: 30 Nm (22 ftlb.) => Final tightening: 90° (67 ftlb.)
Front cardan shaft to transfer box
Information
- The temperature sensor -1- on the transfer box is no longer used in model year 2004.
- If there is no temperature sensor, secure cable plug on the servo motor with tie-wraps.
Plug sequence for transfer box servo motor
10. Connect cable plug -1 , 2- to the transfer box and secure the cable holder.
Cable plug on servo motor
11. Fit heat protection to the cable plugs on the servo motor.
Heat protection on servo motor for transfer box
Subsequent work for transfer gear
Reworking transfer box
1. Install cardan shaft. => 393519 Removing and installing rear cardan shaft - section on "Installing"
2. Fit engine guard. => 108019 Removing and installing engine guard - section on "installing"