Packing boxes, O-rings on transfer case, replacing

/ 9-3 (9440) / 2009 / 4. Transmission / All-wheel drive / Adjustment/replacement / Packing boxes, O-rings on transfer case, replacing

To remove

1.	Remove Transfer case B284 or Transfer case, B207 .

2.	Fit the transfer case in 78 74 878 Floor stand , using 32 025 053 Holder (EN-47642). Loosen 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) with a rubber mallet.

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

6.	Remove the bearing (C), using tool (D) 87 90 982 Ring, pinion bearing to 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 pipe sleeve (B) using tools 83 90 270 Sliding hammer , 87 92 319 Adapter, 3/8" - M10 and 87 92 939 Puller, bearings in gearcase .

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

13.	Remove the seals (A).

14.	Remove the dust cover (A).

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

16.	Lift out the pinion's bearing support (A) and shim (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), shim (B) and position the pinion's bearing support (A).

3.	Fit the bolts (C) Tightening torque: 20 Nm +30 degrees (15 lbf ft +30 degrees) and the packing box (B) using tools DT-49061 Fitting taper and DT-49097 Fitting drift .

4.	Fit the dust cover (A) using DT-49095 Fitting drift

5.	Fit the seals (A) using DT-49093 Fitting drift .

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

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

8.	Fit the input shaft seal (A) using DT-49094 Fitting drift . Fit the input shaft (B).

9.	Fit the seal (A) using DT-49093 Fitting drift

10.	Wipe the mating face clean and apply a bead of Loctite 5970 or similar sealant. Lift the housing into place.

11.	Fit the transfer case bolts (A) using thread locking compound Loctite 243 or the like. Tightening torque: 20 Nm +30 degrees (15 lbf ft +30 degrees)

12.	Fit the circlip (B). Press on the bearing using 87 90 982 Ring, pinion bearing and fit the circlip (A).

13.	Fit DT-49104 Protective collar , tap in the intermediate shaft (A) using tool DT-49103 Fitting drift and a rubber mallet. Remove the collar and apply grease (Molykote P4 or Mobil XHP 222) to the spines. Important Circlip opening towards "whole" surface.

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

15.	Fit the O-ring (A).

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

17.	Fit Transfer case B284 or Transfer case, B207

Our Friends