Disassembly and assembly
1. Disconnect the battery from ground.
2. Raise the car.
3. Drain the oil from the transfer case.
4. Mark the position of the cardan shaft flanges, unscrew the nuts, disconnect the flange and remove the shaft from the transmission (or transfer case).
5. Remove the dust cover, pry up and pull out the oil seal.
6. Assembly is carried out in reverse order.
7. Press the new seal in with a mandrel (mIT3995 and MB990938-01 tools) until the plane of the seal is aligned with the gearbox housing (transfer case).
8. When assembling, align the marks on the cardan shafts that were applied during disassembly.
Removal and installation
1. Disconnect the battery from ground.
2. Remove the transmission assembly with the transfer case.
3. Remove the filling pipe and unscrew the plugs.
4. Remove the retainer spring and plunger (or ball).
5. Remove the spring loaded pin from the transmission shift slider.
6. Loosen the nuts/bolts and remove the transfer case.
7. Note the position of the 2 wire retainers on the transfer case mounting bolts.
8. When separating the crankcases, remove the transfer case lever.
9. Installation is carried out in reverse order.
10. Replace the gasket and install it with 3M ART N 8001 or N 8011 sealant, lubricating both sides. Lubricate the transmission secondary shaft to make it easier to install into the transfer case.
11. Tighten all connections to the required torques.
12. Press the spring-loaded pin (2) into the slider (1) of the transfer case using the MD998245-01 tool (allowed with a beard).
13. The pin groove must be oriented in a certain direction when pressing in (keep the size at 3–3.5 mm) (1 – axis of symmetry of the transfer case control shaft).