Looks like I will be spending some time under the 04 E320 4matic wagon to replace my bad transfer case. Anyone out there know of a link to a on-line procedure? Anyone want to share some tips/experience doing this? A photo of the case out of the car would be great so I can see what all I am removing, particulary location of all the bolt locations going into the transmission.
Wish me luck.
Thanks,
Larry

 

Hi Larry,
not too hard, make sure your car is high enough in the air on 4 jacks, remove both drive shafts, unplug transfercase motor, support transmission with jack stand, remove transfer case support brace, place jack under it and remove 12 bolts holding it to the transmission output flange. You may have to cut 8mm open end wrench in half to make a short one for the top 2 screws to get to them. Move it back about 2 inches and lower it down. I did transmission in my garage on my ML (and engine together with transmission out of my 126 all by myself). Your tranny and transfer case should be same as my in ML, 722.6 type. Good luck.
Bernard

 

Thanks for the reply and great pix. Was wondering about the access to bolts I assume are on top. Think I will get one of those stubby ratcheting wrenches for that.
Cheers.

 

they are torx bolts but a 10mm box wrench will do the job for 1 or 2 bolts that are in a tight spot with minimal access. a racheting one will work. but also the proper torx bit with an extension and a swivel will help too. also youll need a 13mm box wrench because some of the bolts have 13mm nuts on the end. and a 16mm to remove the tranfer case support braket and also the rear transmount. and small hex sockets or allen wrenches( careful not to overtighten cause they commonly do break off they have loktight on them to keep them in.) to remove the front drive shaft from the transfercase..... and i think 17 and 18 or 19mm to remove the rear driveshaft from the transfercase. there is no electrical plug on this particular transfercase. the torx bolts are E12 or E14 but i think they are E12s and there are 2, 13mm nuts on the other side of the torx bolts and 2 more 13mm or the bottom of the transfercase. and yes the rear drive shaft will just push to the side, up or down to remove the case. there are 2 dowels holding the case in place so remember to put them back in. clean off and lube the gears where the case meets the trans..just some antiseize or vaseline will do. pretty easy if you have a lift and a pole jack to support the trans while removing the cross support bar.

 

Good point chassis221, I have low/high gear motor with plug on my ML, this option is not on E-class 4-matic, so no electrical connection. Driveshaft (front and rear) bolts are all 16mm hex head on ML, short 6-point swivel socket works well.

 

Thanks for the update.
So the rear driveshaft, once disconnected from the output flange, can be pushed back far enough to remove the x-fer case without completely removing the shaft? Chassis211, you know offhand which size torx? I have no external torx sockets so I need to get it. Right tool, right job thing ya know! Any gaskets, stretch bolts, ect. I should have on hand when starting?

Now, finding a x-fer case that is on a shelf and was not suppose to be recalled when it was in a 05/06 is my mission. None in my state.

 

What is the initial problem with the transfer case and what was the symptoms?
How many miles..?

Thanks

2004 E-500 Wagon