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Remove/Install Transfer Case - AR28.10-P-0100OLC

Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 

with code M005 (Vehicles with 4MATIC/all-wheel drive) 

Shown on model 213 with engine 276.8 

G13745610Courtesy of MERCEDES-BENZ USA
G13745611Courtesy of MERCEDES-BENZ USA

Shown on transmission 725.0 with engine 276.8 

Fig 1: Transfer Case Components Location - Transmission 725.0 In Model 213 (Except 213.088/089/288/289) With Code M005 (Shown With Engine 276.8)
G13745612CAUTIONCAUTIONWARNINGREMOVINGINSTALLINGINSTALLATION IMPORTANTREFER TO SHOP-MADE TOOLSTORQUE SPECIFICATIONTORQUE SPECIFICATIONSPECIAL TOOLTORQUE SPECIFICATIONREFER TO SPECIAL TOOLSREFER TO SPECIAL TOOLSINSTALLATION IMPORTANTIMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONDISASSEMBLINGWARNINGWARNINGCourtesy of MERCEDES-BENZ USA
  Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
CAUTION Risk of injury  to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.		 AS00.40-Z-0001-01A
CAUTION Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
WARNING Risk of injury.  Skin or eye injuries may result when handling hot or glowing objects. Wear protective gloves, protective clothing and safety glasses, if necessary. AS00.00-Z-0002-01A
  Notes on bolted connections with self tapping screws   AH00.00-P-0007-01SF
  Notes on threaded connections fastened using a tightening angle-based tightening process   AH00.00-P-0020-01A
  Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
  Notes on threaded connections with aluminum screws/bolts   AH00.00-P-0006-01RM
  Notes on automatic transmission   AH27.19-P-0001-01NKB
REMOVINGINSTALLING Remove/install     
1 Shift the transmission (5) into neutral position.    
2 Secure vehicle to prevent it moving away.    
3 Release parking brake.    
4 Secure vehicle on vehicle lift.   AR00.60-P-1006A
5 Remove center and rear lower engine compartment lining. INSTALLATION IMPORTANT : Install center and rear lower engine compartment lining after the leak test. AR61.20-P-1105LWE
6 Remove exhaust system. Transmission 725.0 in model 213 (except 213.088/089/288/289) with engine 274.9 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR49.10-P-7142MRD
    Transmission 725.0 in model 238 with engine 274.9
with code M005 (Vehicles with 4MATIC/all-wheel drive)		 AR49.10-P-7142MRC
    Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 with engine 276.8 with code M005 (Vehicles with 4MATIC/all-wheel drive)
except code 598 (Gasoline particulate filter (OPF) with sensor system)		 AR49.10-P-7142MND
    Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 with engine 654 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR49.10-P-7142OLC
    Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 with engine 642 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR49.10-P-7142OGW
    Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 with engine 656 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR49.10-P-7142OIB
    Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 with engine 256.9 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR49.10-P-7142MSA
    Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 with engine 264 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR49.10-P-7142MRH
7 Remove heat shield behind the transmission (5).    
8 Remove propeller shaft (3) from output flange of transfer case (7), slide backward and secure against falling down.   AR41.10-P-0040-01LW
REFER TO SHOP-MADE TOOLS     WF58.50-P-4110-01A
    TORQUE SPECIFICATION Transmission 725.0 in model 238 with code M005 (Vehicles with 4MATIC/all-wheel drive) Flexible coupling to transmission/rear axle differential or propeller shaft *BA41.10-P-1001-01N 
    TORQUE SPECIFICATION Transmission 725.0 in model 213 (except 213.088/089/288/289)
with code M005 (Vehicles with 4MATIC/all-wheel drive) Flexible coupling to transmission/rear axle differential or propeller shaft		 *BA41.10-P-1001-01M 
    SPECIAL TOOL Counterholder Fig 3
9 Remove rear engine mount (2). Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 with engine 276.8 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR22.10-P-1160MND
    Transmission 725.0 in model 213 (except 213.088/089/288/289) with engine 274 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 with engine 642 with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 with engine 654 with code M005 (Vehicles with 4MATIC/all-wheel drive)		 AR22.10-P-1160OLC
    Transmission 725.0 in model 213, 238 with engine 264
with code M005 (Vehicles with 4MATIC/all-wheel drive)
Transmission 725.0 in model 238 with engine 274.9
with code M005 (Vehicles with 4MATIC/all-wheel drive)		 AR22.10-P-1160MRD
    Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 with engine 656 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR22.10-P-1160OIB
    Transmission 725.0 in model 213 (except 213.088/089/288/289), 238 with engine 256.9 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR22.10-P-1160MSA
10 Unscrew screws (10) and remove vibration damper (9). TORQUE SPECIFICATION Bolt, vibration damper to transfer case *BA28.10-P-1008-01G 
11 Lower transmission (5) until all screws (6) on the circumference of the transfer case (7) are accessible.    
12
REFER TO SPECIAL TOOLS		 Support transfer case (7).
000 588 10 62 00 Support plate		   WS26.00-P-3309B
REFER TO SPECIAL TOOLS 000 588 11 62 00 Major assembly mount   WS01.00-P-0092B
13 Unscrew screws (6) and remove transfer case (7). INSTALLATION IMPORTANT : Before mounting the transfer case (7) coat the gearing of the transmission's output shaft (5) with grease.
IMPORTANT The aid of a second person is required for disconnection and connection at the flange of the front axle propeller shaft (4).
Klueber Microlube GNY 202		 *BR00.45-Z-1071-06A 
    TORQUE SPECIFICATION Bolt, transfer case to automatic transmission *BA28.10-P-1001-01G 
14 Check intermediate panel (8) for damage. If problems occur,
↓
Replace intermediate panel (8).		  
15 Install in the reverse order.    
  Concluding tasks     
16 Check and correct oil level of transfer case (7). Transmission 725.0 (except 725.06/09) in model 213 (except 213.088/089/288/289), 238
with code M005 (Vehicles with 4MATIC/all-wheel drive)		 AR28.10-P-0100-06A 
    TORQUE SPECIFICATION Transfer case oil *BF28.10-P-1001-01F 
    TORQUE SPECIFICATION Oil level sight glass to transfer case *BA28.10-P-1007-01G 
    TORQUE SPECIFICATION Drain screw to transfer case *BA28.10-P-1003-01G 
    Assembly cleaner *BR00.45-Z-1028-04A 
    DISASSEMBLING Hand pump Fig 2
WARNING Risk of burn injuries,  suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning  caused by skin contact with solid components of the exhaust. Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area. AS49.00-Z-0001-01A
WARNING
17		 Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running.
Perform engine test run and check transfer case (7) for proper operation and leak tightness.		 Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
COMPLETE TRANSFER CASE

Number Designation Model 205, 213, 217, 218, 222, 223, 238, 253, 257, 290 with transmission 725.0/1
with code M005 (Vehicles with 4MATIC/all-wheel drive)
BA28.10-P-1001-01G Bolt, transfer case to automatic transmission Stage 1 Nm 30
Stage 2 ∠° 90
COMPLETE TRANSFER CASE

Number Designation Model 205, 213, 217, 218, 222, 223, 238, 253, 257, 290
with transmission 725.0/1
with code M005 (Vehicles with 4MATIC/all-wheel drive)
BA28.10-P-1003-01G Drain screw to transfer case Nm 25
COMPLETE TRANSFER CASE

Number Designation Model 205, 213, 217, 218, 222, 223, 238, 253, 257, 290
with transmission 725.0/1
with code M005 (Vehicles with 4MATIC/all-wheel drive)
BA28.10-P-1007-01G Oil level sight glass to transfer case Nm 11
COMPLETE TRANSFER CASE

Number Designation Model 205, 213, 217, 218, 222, 223, 238, 253, 257, 290
with transmission 725.0/1
with code M005 (Vehicles with 4MATIC/all-wheel drive)
BA28.10-P-1008-01G Bolt, vibration damper to transfer case Nm 39
PROPELLER SHAFT

Number Designation Model 213
BA41.10-P-1001-01M Flexible coupling to transmission/rear axle differential or propeller shaft Direct threaded connection Stage 1 Nm 60
Stage 2 ∠° 90
PROPELLER SHAFT

Number Designation Model 238
BA41.10-P-1001-01N Flexible coupling to transmission/rear axle differential or propeller shaft Direct threaded connection Stage 1 Nm 60
Stage 2 ∠° 90
COMPLETE TRANSFER CASE

Number Designation Models 205, 213, 217, 218, 222, 238, 253, 257, 290 with transmission 725.0
BF28.10-P-1001-01F Transfer case oil Filling capacity Liter 0, 65
Specification Sheet   BB00.40-P-0236-15A
Fig 2: Identifying Hand Pump (210 589 00 71 00)
G13745613Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Counterholder (176 589 00 40 00)
G11128638Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner A 000 986 56 01
BR00.45-Z-1071-06A Klueber Microlube GNY 202 A 001 989 44 51 10
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