Remove/install transfer case absolute sensor - AR28.19-P-1009GZ

MODEL 164 with CODE (430) Offroad package 

Fig 1: Identifying Transfer Case Actuator Motor, Transfer Case Absolute Sensor And Rear Engine Crossmember

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
1	Remove heat shield in front of transfer case actuator motor (M46/2)
2	Separate connector at transfer case absolute sensor (B57)
3.1	Disconnect exhaust system to flange connection between catalytic converter and center muffler	Risk of breakage!  In order to protect the exhaust system against distortion. Vehicles with gasoline engine.
3.2	Separate exhaust system at hose clamp between diesel particulate filter and pipeline exhaust	Risk of breakage!  In order to protect the system against distortion. Vehicles with diesel engine 642.
3.3	Separate exhaust system at hose clamp and flange connection between diesel particulate filter and pipeline	Risk of breakage!  In order to protect the exhaust system against distortion. Vehicles with diesel engine 629.
4	Remove cross strut
5	Loosen bolt of diagonal strut on engine crossmember	Fold diagonal strut of engine crossmember to one side.
6	Support transfer case (1) using transmission jack and transmission platform
		Passenger car transmission platform, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com  Telescoping transmission jack, refer to GOTIS http://gotis.aftersales.daimlerchrysler.com
7	Loosen bolts on rear engine crossmember to body	Removal: Only  lower transfer case (1) using transmission jack until the bolts (3) on the transfer case absolute sensor (B57) are accessible.
8	Loosen bolts (3) on transfer case absolute sensor (B57) from transfer case (1)
9	Remove transfer case absolute sensor (B57)
	Install
10	Grease sealing ring on transfer case absolute sensor (B57) lightly
11	Install transfer case absolute sensor (B57)	Mount the transfer case absolute sensor (B57) carefully otherwise the sealing ring may be destroyed.
		Sealant	*BR00.45-Z-1013-01A
12	Tighten bolts (3) of transfer case absolute sensor (B57) on transfer case (1)		*BA28.19-P-1003-01C
13	Fasten rear engine crossmember to body		*BA22.10-P-1005-03G
14	Install cross strut		*BA22.10-P-1006-03G
			*BA22.10-P-1008-03G
15	Install bolt of diagonal strut on engine crossmember		*BA22.10-P-1007-03G
			*BA22.10-P-1009-03G
16	Connect connector (3) to transfer case absolute sensor (B57)
17	Install heat shield in front of transfer case actuator motor (M46/2)
18.1	Connect exhaust system at flange connection between catalytic converter and center muffler	Vehicles with gasoline engine.
		Engine 272, 273	*BA49.10-P-1003-01W
		Engine 272, 273	*BA49.10-P-1004-01W
		Engine 113	*BA49.10-P-1003-01S
		Engine 113	*BA49.10-P-1004-01S
18.2	Connect exhaust system at hose clamp between diesel particulate filter and pipeline	Vehicles with diesel engine 642.
	Hose clamp, diesel particulate filter at rear muffler		*BA14.40-P-1007-01B
18.3	Separate exhaust system at hose clamp and flange connection between diesel particulate filter and pipeline	Vehicles with diesel engine 629.
	Hose clamp, diesel particulate filter at rear muffler		*BA14.40-P-1007-01B
	Flange connection, diesel particulate filter at rear muffler		*BA14.40-P-1008-01B
19	Perform calibration with STAR DIAGNOSIS, read out fault memory, clear	Menu item: Transfer case → Control units adaptations → Calibration.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A

TRANSFER CASE ELECTRICAL SYSTEM

Number	Designation		Model 164.1/8
BA28.19-P-1003-01C	Bolt, absolute sensor to transfer case	Nm	7

ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

Number	Designation		Model 164
BA22.10-P-1005-03G	Bolt, rear engine crossmember to body	Nm	55
BA22.10-P-1006-03G	Bolt for cross strut on engine crossmember	Nm	45
BA22.10-P-1007-03G	Bolt for diagonal strut on engine crossmember	Nm	45
BA22.10-P-1008-03G	Bolt for cross strut on body	Nm	45
BA22.10-P-1009-03G	Bolt for diagonal strut on body	Nm	45

EXHAUST SYSTEM

Number	Designation		Engines 272, 273 in model 164
BA49.10-P-1003-01W	Self-locking nut of rear muffler flange connection to three way catalytic converter	Nm	20
BA49.10-P-1004-01W	Bolt for center muffler flange connection on catalytic converter	Nm	35

EXHAUST SYSTEM

Number	Designation		Engine 113.964 in model 164.1
BA49.10-P-1003-01S	Self-locking nut of rear muffler flange connection to three way catalytic converter	Nm	20
BA49.10-P-1004-01S	Bolt for center muffler flange connection on catalytic converter	Nm	35

DIESEL PARTICULATE FILTER

Number	Designation		Engine 629 with code 474 in model 164	Engine 642 with code 474
BA14.40-P-1007-01B	Hose clamp, diesel particulate filter at rear muffler	Nm	35	20
BA14.40-P-1008-01B	Flange connection, diesel particulate filter at rear muffler	Nm	20	20

AUXILIARY REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Sealant	A 003 989 98 20