Stuffing boxes, O-rings, transfer case, replacement

/ 9-3 (9440) / 2011 / 4. Transmission / All-wheel drive / Adjustment/replacement / Stuffing boxes, O-rings, transfer case, replacement

To remove

1.	Remove Transfer case, B207

2.	Fit the transfer case in 78 74 878 Floor stand , use 32 025 053 Holder (EN-47642). Loosen the drain plug (A) and drain the fluid. Important Circlip opening towards "whole" surface.

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

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

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

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

7.	Remove the O-ring (A).

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

9.	Remove the seal (A).

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

11.	Remove the O-ring (A) and tubular 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.	Dismantle the dust cover (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 on the pinion. Remove the O-ring (C).

To fit

1.	Remove the sealing compound from the mating surface.

2.	Fit the O-ring (C), shims (B) and insert the pinion bearing support (A) in position.

3.	Fit the bolts (C). Tightening torque 20 Nm +30 degrees (15 lbf ft +30 degrees) and the stuffing box (B) use tool: DT-49061 Climbing cone and DT-49097 Fitting drift .

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

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

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

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

8.	Fit the input shaft 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 surface and apply a bead of sealing compound Loctite 5970 or the like and lift the housing into position.

11.	Fit the transfer case bolts (A), use thread locking adhesive 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 use tool: 87 90 982 Ring, pinion bearing and fit circlip (A).

13.	Fit DT-49104 Protective collar , knock in the intermediate shaft (A), use tool: DT-49103 Fitting drift and a rubber mallet. Remove the protection and apply grease on 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 0.65 litres Burmah Castrol SAF PD SAE 75W 85 93 165 383 Transfer case fluid in the transfer case.

17.	Fit Transfer case, B207

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