Campaign - Transfer Case Inspection/Replacement
FILE:SERVICE: GROUP 00 OF SERVICE INFORMATION BINDER
PARTS: GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER
Campaign No. 2007100004, February 2009
Revision History
Revision Date Purpose
D 02/13/09 Revision to warranty information for model 203
C 01/23/09 Inclusion of model 203 (revisions to procedure, parts, warranty information)
B 12/20/07 Addition to Parts Table
A 12/12/07 Addition to Parts Table, and revised Work Instructions
- 12/07/07 Initial issue
TO: ALL MERCEDES-BENZ CENTERS
SUBJECT:
MODELS 203/211/220 4MATIC
MODEL YEARS 2005 - 2007
REPLACE TRANSFER CASE
This Service Campaign has been initiated because DCAG has determined that on the affected vehicles optimized transfer cases will reduce vibrations when cornering or when parking. Dealers will check a serial number on the transfer case and replace the transfer case on affected vehicles, if required, during the next workshop visit.
Prior to performing this Service Campaign:
^ Please check VMI to determine if the vehicle is involved in the Campaign and if it has been previously repaired.
^ Please review the entire Service Campaign bulletin and follow the procedure steps exactly as described.
Please note that Recall and Service Campaigns do not expire and may also be performed on a vehicle with a vehicle status indicator.
Approximately 12,880 vehicles are affected.
Check/Test Procedure
1. Remove rear engine compartment paneling.
2. Check serial number at transfer case (A, Figure 1)
a) If serial number is between 115925 and 137342: Carry out work procedure.
b) If serial number is not between 115925 and 137342: Reinstall rear engine cover - end measure.
Note:
Do not replace transfer case if numbers 0085 are indicated after the serial number regardless if transfer case falls in the serial number range or not.
Procedure
Note:
Refer to the MSDS (via NetStar or the Parts Assistance Center website) for a complete description of hazards and other important safety information.
1. Replace transfer case, for models shown above.
Note:
^ Reuse dowel pins for transfer case. If dowel pins remain in transfer case housing after removal (of transfer case), they must be removed and reinstalled into transmission dowel bores.
^ DO NOT REUSE Transfer Case front drive shaft bolts and rear drive shaft nuts. Always use new fasteners (self locking nuts, self locking bolts). See Parts Table.
DO NOT RE-USE Catalytic Converter Bracket nuts. Always use new fasteners (self locking nuts). See Parts Table.
2. Transfer case return information:
^ DRAIN ALL GEAR OIL FROM OLD TRANSFER CASE OUT THE DRAIN HOLE BEFORE REPACKAGING.
^ Ensure plugs from drain hole, filler hole and vent port are installed.
^ Secure old transfer case together for shipping using 4 transport bolts (A, Figure 2) and 4 nuts (arrows) included with new transfer case. Torque nuts (arrows) to 25 Nm.
^ Ensure removed transfer case is returned in same packaging that contained the new one:
- Ensure that the old transfer case is not damaged during removal or packaging.
- The supporting card board inserts provided must be reused during packaging. The old transfer case must be packaged in the same manner as was the new one (refer to Figures 3-6 above).
^ Generate bar code label and return it with the old transfer case.
^ Print out and complete return slip (shown above) and place inside transfer case shipping box. The serial number (A, Figure 1) is stamped on the old transfer case
Note:
(regarding WIS work instructions AR28.10-P-0100T/AR28.10-P-0100I/ AR28.10-P-0100P)
The new transfer case will be shipped filled with transfer case fluid. It should not be necessary to add an additional 0.59 L of transfer case fluid to the new transfer case as indicated in the WIS instructions. However, as indicated previously in this procedure; the fluid level in the new transfer case must still be checked and topped off if necessary.
Primary Parts Information
Note:
^ Please be aware that only the part number(s) referenced in the Campaign Bulletin is/are approved for use to repair the vehicle. Repairs performed using any other part(s) will not have been performed in accordance with the campaign. Accordingly, warranty claims submitted with reference to an improper part number(s) will be denied.
^ The following allowable labor operation should be used when submitting a warranty claim for this repair:
Warranty Information