AR28.10-P-1000B Disassemble/assemble transfer case 2.3.

12
MODEL 463.200 /204 /207 /220 /221 /224 /225 /227 /228 /304 /307 /324 /325 /327 /328 with TRANSFER CASE 750.650
MODEL 463.228 /300 /320 /321 with TRANSFER CASE 750.651
MODEL 463.200 /204 /207 /220 /221 /224 /225 /227 /228 /304 /307 /324 /325 /327 /328 with TRANSFER CASE 750.652
MODEL 463.206 /208 /209 /230 /231 /232 /233 /240 /241 /308 /330 /331 with TRANSFER CASE 750.653

Shown on transfer case 750.653

1 Gearshift lever
2 Gearshift lever cover
3 Shift fork
4 Shift cylinder housing
5 Diaphragm
6 Differential lock shift mechanism
7 Front transmission cover
8 Housing
9 Intermediate flange
10 Bearing cap
11 Intermediate flange cover
12 Speedometer drive
13 Speedometer output
14 Input shaft
15 Countershaft
16 Differential

P28.10-2007-06

Disassemble
1 Remove transfer case AR28.10-P-0100B
2 Mount transfer case on assembly stand. AR28.10-P-1000-16B
Assembly stand *116589065900
Bracket *463589006300
3 Detach gearshift lever cover (2) If the gearshift lever cover is damaged: AR28.60-P-1002-01B
Disassemble/assemble gearshift lever cover AR28.60-P-1002B
(2).
4 Removing coupling flanges Mark installed position. AR28.10-P-1000-09B
Retainer wrench *460589013100
Puller *460589023300
5 Remove shift cylinder housing (4) and AR28.60-P-1001-02B
diaphragm (5).
6 Remove front transmission cover (7). If transmission cover is damaged: AR28.40-P-0100B
Disassemble / assemble transmission AR28.40-P-0200B
housing cover (7).
7 Remove differential lock shift mechanism (6) AR28.60-P-1008GM
8 Remove cover AR28.40-P-1000-17B
9 Remove speedometer drive (12) If the speedometer drive is damaged: AR28.40-P-1001B
Disassemble/assemble speedometer drive AR28.40-P-1002B
(12).
10 Remove bearing cap (10) at intermediate If bearing cover is damaged: AR28.40-P-1003B
flange
Disassemble/assemble bearing cap (10). AR28.40-P-1004B
11 Remove differential (16) If differential is damaged: AR28.50-P-1023B
Replace differential (16), AR28.50-P-1024B
Re-adjust bearing, if necessary:
Disassemble differential (16). AR28.50-P-1025B
12 Remove input shaft (14) and countershaft (15) If countershaft is damaged AR28.50-P-1019B
or input shaft is damaged:
Disassemble drive shaft (14), if necessary: AR28.50-P-1017B
Disassemble countershaft (15). AR28.50-P-1018B
13 Clean all parts, check and replace if The transmission housing (8) may only be
necessary replaced together with the intermediate flange
(9).
Assemble
© Daimler AG, 4/8/24, L/10/16, ar28.10-p-1000b, Disassemble/assemble transfer case Page 1 of 3
MODEL 463.200 /204 /207 /220 /221 /224 /225 /227 /228 /304 /307 /324 /325 /327 /328 with TRANSFER CASE 750.650 MODEL 463.228 /300 /320 /321 with TRANSFER CASE 750.651 ...
14 Install input shaft (14) and countershaft (15) AR28.50-P-1019B
15 Install differential (16) Only up to step 8 AR28.50-P-1023B
16 Install bearing cap (10) at intermediate flange AR28.40-P-1003B
17 Install speedometer drive (12) AR28.40-P-1001B
18 Install differential lock shift mechanism (6) AR28.60-P-1008GM
19 Install front transmission cover (7). AR28.40-P-0100B
20 Install shift cylinder housing (4) and AR28.60-P-1001-03B
diaphragm (5).
Shift piston *BA28.10-P-1005-01B
Shift cylinder *BA28.10-P-1006-01B
*BR00.45-Z-1010-01A
21 Installing coupling flanges AR28.10-P-1000-10B
*BA28.50-P-1001-01B
Retainer wrench *460589013100
*BR00.45-Z-1048-06A
22 Attach cover AR28.40-P-1000-17B
*BA28.40-P-1022-01A
*BR00.45-Z-1092-02A
23 Install gearshift lever cover (2) AR28.60-P-1002-01B
*BA28.40-P-1019-01A
*BR00.45-Z-1010-01A
24 Remove transfer case from assembly stand. AR28.10-P-1000-16B
*BA28.40-P-1018-01A
25 Install transfer case AR28.10-P-0100B

Transfer case gear set, shafts

Number Designation Model 463

BA28.50-P-1001-01B Bolt, flange to shaft Nm 84

Transfer case housing

Number Designation Model 461, 463

with VG 750.65

BA28.40-P-1018-01A Supporting arms on transmission housing M10 Nm 49

BA28.40-P-1019-01A Mounting of gearshift lever cover M8 Nm 22

BA28.40-P-1022-01A Cover to transmission housing M8 Nm 25

Transfer case complete

Number Designation Model

460, 461, 463
with transfer
case 750.6

BA28.10-P-1005-01B Shift piston to shift rod M10 Nm 25

BA28.10-P-1006-01B Shift cylinder to transmission housing M6 Nm 10

© Daimler AG, 4/8/24, L/10/16, ar28.10-p-1000b, Disassemble/assemble transfer case Page 2 of 3

MODEL 463.200 /204 /207 /220 /221 /224 /225 /227 /228 /304 /307 /324 /325 /327 /328 with TRANSFER CASE 750.650 MODEL 463.228 /300 /320 /321 with TRANSFER CASE 750.651 ...
 116 589 06 59 00 460 589 01 31 00 460 589 02 33 00 463 589 00 63 00
Assembly stand Retainer wrench Puller Bracket

Repair materials
Number
BR00.45-Z-1010-01A
BR00.45-Z-1092-02A
BR00.45-Z-1048-06A
Designation Order number
Hylomar universal sealant 80 ml A 001 989 25 20
Adhesive kit, body, 2-component adhesive A 009 989 36 71
Loctite anti-seize Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 München
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de

© Daimler AG, 4/8/24, L/10/16, ar28.10-p-1000b, Disassemble/assemble transfer case Page 3 of 3

MODEL 463.200 /204 /207 /220 /221 /224 /225 /227 /228 /304 /307 /324 /325 /327 /328 with TRANSFER CASE 750.650 MODEL 463.228 /300 /320 /321 with TRANSFER CASE 750.651 ...