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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| Transfer Case rubber mounts
I just completed rebuilding my propeller shaft. In the process of ordering all parts, I thought I would replace the TC mounts. There are three.. The old mounts have color markings, Blue, White, Yellow. Only one of the new mounts came with the smallest Blue dot. Seems the Blue mount has a different durometer to the rubber. This one I could match with the old, but I couldn't tell what order to place the other two mounts. Any thing I should consider or assume the other two mounts are identical and it doesn't matter? Also, I could not find torque specs for the mounts? Thank you guys |
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| Re: Transfer Case rubber mounts
Why is it so damn hard to locate a real service manual for this vehicle?
I bought a CD, "Mercedes G500 Repair manual" for $55, it's the most useless form of repair manual I've ever wasted money on.. Everything is in general, a part locator at best!
I need an old fashioned step by step repair manual that gives torque specs, bolt hardness specs, part configuration, so on and so on?
Can anyone direct me, at any cost, to a proper, "Service Manual", CD, online service or anything I can hold and control?
I'm not one who likes to ask for help..
I like to do my own repairs, I'm no idiot but the lack of good solid repair info on these trucks, makes me feel so! |
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DUTCH
Administrator Doppelgänger
Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
| Re: Transfer Case rubber mounts
You need a copy of the Workshop Information System (WIS). It can be had on a hard drive from various pirates. |
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DUTCH
Administrator Doppelgänger
Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
| RE: Transfer Case rubber mounts
There are three different mounts. P/N ending in 01.86 is the left rear, 02.86 is the right rear and 03.86 is the front. |
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Floobydust
Veteran
Date registered: Mar 2014
Location: Massachusetts, USA
Vehicle(s): 1995 E320 Cabrio, 2003 G500, 2000 SL500, 1980 TR8
Posts: 284
| Re: Transfer Case rubber mounts
I went for the same "manual" as well and have to say also that I was sorely disappointed. From what I have gleaned over time, detailed service information comes mostly from the WIS (workshop information system), and probably more importantly, pdf printouts from the WIS system. There also seems to be a fairly complete service manual available for the W461 trucks, much of which applies to the later W463 trucks. Somewhere I would like to find a complete WIS "dump" because using the WIS is a bit of a PITA.
I replaced my TC mounts with three "white" units per this Mercedes service bulletin ( http://workshop-manuals.com/mercedesbenz/g_55_amg_%28463.246%29/v8-... ) as part of chasing the vibration issue I have been having. It didn't help, so I probably have three slightly used, but good TC mounts in my basement.
As for the detailed procedure for TC mount replacement, a link to one of those PDFs is here: http://fourbyfourclub.com/Manuals/W463TransferCaseMountsInstallatio... Unfortunately, even that may not give you enough information as it does not seem to say which TC mount goes where based on its color, but I think this table may help:
463 280 03 86 Front (Blue)
463 280 02 86 R Rear (Yellow)
463 280 01 86 L Rear (White)
Hope this helps.
- FD
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AlanMcR
Expert
Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
| RE: Transfer Case rubber mounts
Printed procedural manuals died out with the arrival of the MBUSA models. That being said, much of the modern G is strongly related to the pre-MBUSA W463. The axles, the transmission, (most of) the transfer case, and the body are easily understood through the old manuals. The electrical system is completely different.
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DUTCH
Administrator Doppelgänger
Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
| Here You Go
Well, it's interesting that the WIS sheet shows that the bolts have a torque spec (Nm), but doesn't give the values. That's quite unusual.
I was finally able to track them down in another WIS sheet.
The M10 bolts that hold the support to the TC housing are 49 Nm.
The M12 bolt holding the support to the rubber mount is 78 Nm.
The M8 bolts holding the rubber mount to the frame are 21 Nm.
Hope this info helps. Merry Christmas! 
Attachments
----------------
 Remove_install transfer case rubber mounts.pdf (54KB - 26 downloads)
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Gilamonster
Veteran
Date registered: Sep 2013
Location: New Mexico
Vehicle(s): G #1 (mix of a 460, 461 & 463), #2 is a 2000 G500
Posts: 151
| Re: Transfer Case rubber mounts
NHDave - 12/22/2014 3:29 PM
Why is it so damn hard to locate a real service manual for this vehicle?
I bought a CD, "Mercedes G500 Repair manual" for $55, it's the most useless form of repair manual I've ever wasted money on.. Everything is in general, a part locator at best!
I need an old fashioned step by step repair manual that gives torque specs, bolt hardness specs, part configuration, so on and so on?
Can anyone direct me, at any cost, to a proper, "Service Manual", CD, online service or anything I can hold and control?
I'm not one who likes to ask for help..
I like to do my own repairs, I'm no idiot but the lack of good solid repair info on these trucks, makes me feel so!
I sent you a pm. |
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| Re: Transfer Case rubber mounts
Thank you guys.
That's a big help!
I wish you all lived close by, we could sip some holiday spirits.
Happy Holiday's |
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| A revisit surprise to me!
Thank you all for your help this past week. An update for you all... So I climb under the truck to double check all my TC rubber mounts positioning and their torque settings,,, and to my surprise, I see CV grease tossed from both my large CV clamps! These CV Oetiker clamps require an Oetiker pincer plier to apply, I did exactly so, almost to the point of breakage! I can not believe, I now need to revisit this whole process once again! I have no idea how much grease was tossed but I can see more than a 1/2" build up where it collected....... I believe these kit clamps are oversized?I should have not gone with the rebuild kit offered from Euro truck or otheres but listened to 4x4abc, and go with a new shaft to avoid this BS! I'm beside myself right now!!!!!!! WTF!! I don't know what I thought I was saving, going this route. Perhaps less landfill material, only to add more after all said and done? I'll be ordering a factory shaft tonight! DJust venting, thanks for reading |
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DUTCH
Administrator Doppelgänger
Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
| RE: A revisit surprise to me!
Order the GKN shaft from ET, and save a few bucks. |
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atg
Veteran
Date registered: Nov 2014
Location: Los Angeles
Vehicle(s): 2005 G55, 1985 300tdt
Posts: 129
| Re: Transfer Case rubber mounts
Is this some sort of mystery book? Or am I completely on the hook for a star xentry c3 multiplexer hard drive and laptop? They are everywhere on ebay so its hardly a secret! Missing the paper manuals for my 1963 diesel fintail! I had the parts manual and a service manual for that car. Very handy.
Mercedes is missing opportunities to sell me this stuff. I would pay a reasonable amount for it, but not thousands of dollars. |
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| RE: A revisit surprise to me!
DUTCH - 12/27/2014 9:13 PM Order the GKN shaft from ET, and save a few bucks. Hi Dutch My new CV joints are from ET and they are GKN. I did not go with a new shaft assembly though, just the kits. My mistake. |
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| Re: Transfer Case rubber mounts
atg - 12/27/2014 9:18 PM Is this some sort of mystery book? Or am I completely on the hook for a star xentry c3 multiplexer hard drive and laptop? They are everywhere on ebay so its hardly a secret! Missing the paper manuals for my 1963 diesel fintail! I had the parts manual and a service manual for that car. Very handy. Mercedes is missing opportunities to sell me this stuff. I would pay a reasonable amount for it, but not thousands of dollars. There is no book that I know of, all cyber these days or WIS with STAR
Edited by NHDave 12/27/2014 9:59 PM
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| Re: Transfer Case rubber mounts
So here I go again, 12 new nuts, three hours and a new shaft towards ownership!
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atg
Veteran
Date registered: Nov 2014
Location: Los Angeles
Vehicle(s): 2005 G55, 1985 300tdt
Posts: 129
| RE: A revisit surprise to me!
Maybe they were just too full of grease?
I dont know if this manual would apply or not for those shafts
https://www.dropbox.com/s/erkqlwljml2z0zs/SERVICE%20MANUAL_Mercedes_... |
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Floobydust
Veteran
Date registered: Mar 2014
Location: Massachusetts, USA
Vehicle(s): 1995 E320 Cabrio, 2003 G500, 2000 SL500, 1980 TR8
Posts: 284
| RE: A revisit surprise to me!
I made the same error - I bought the GKN CV joint kit and rebuilt the homokinetic shaft on my G. I too found the grease ring of shame neatly painted on the underside of the transmission tunnel! There seems to be two things one must pay attention to when fitting a new CV joint - first. the blue sealant provided in the kit must be applied in adequate amounts to prevent the expulsion of grease from the centrifugal force, and second, the boot clamps must be tight enough to prevent leakage there. On the postmortem of my re-built shaft, I had one of each based on where the grease ring appeared on the trans tunnel.
After that little melt down, I went with a genuine MB HK shaft (ET was out of stock on the GKN ones at the time) because I didn't want to spend time trouble shooting the sources of the leaks. I know better now, so I have rebuilt by old shaft as well so now I have a spare.
After all of that, I still have the vibration issue which I think is going to require a new transfer case to resolve.
- FD
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DUTCH
Administrator Doppelgänger
Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
| RE: A revisit surprise to me!
NHDave - 12/27/2014 9:56 PM
DUTCH - 12/27/2014 9:13 PM Order the GKN shaft from ET, and save a few bucks. Hi Dutch My new CV joints are from ET and they are GKN. I did not go with a new shaft assembly though, just the kits. My mistake.
I was talking about the entire GKN shaft, not just the CV joints. If/when it becomes necessary on my G, that's the way I would go; although MB shaft from the right discounting dealer is not too much more expensive than the GKN. |
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DUTCH
Administrator Doppelgänger
Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
| RE: A revisit surprise to me!
Floobydust - 12/28/2014 12:25 AM
After all of that, I still have the vibration issue which I think is going to require a new transfer case to resolve.
- FD
Have you considered replacing the rear engine mount - the one that supports the tail of the tranny? If that is worn and out of line, that could be another source. When I did this on my 280GE, there was a definite improvement. |
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Floobydust
Veteran
Date registered: Mar 2014
Location: Massachusetts, USA
Vehicle(s): 1995 E320 Cabrio, 2003 G500, 2000 SL500, 1980 TR8
Posts: 284
| RE: A revisit surprise to me!
DUTCH - 12/28/2014 6:52 AM
Have you considered replacing the rear engine mount - the one that supports the tail of the tranny? If that is worn and out of line, that could be another source. When I did this on my 280GE, there was a major improvement.
Thanks for the suggestion, but I've already done that and it made no difference. In fact, at this point I have replaced every rubber interface on the entire drive train and suspension. The truck drives like a dream except for that vibration.
Just before Christmas I did one last "maximum perturbation" on the transfer case where I flipped the homokientic shaft front to back and rotated in 180 degrees in the coupling flanges. The idea was to see if anything changed related to the vibration and it didn't. So at this point I can only conclude that there is something amiss in the TC itself. |
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Floobydust
Veteran
Date registered: Mar 2014
Location: Massachusetts, USA
Vehicle(s): 1995 E320 Cabrio, 2003 G500, 2000 SL500, 1980 TR8
Posts: 284
| RE: A revisit surprise to me!
DUTCH - 12/28/2014 6:50 AM
I was talking about the entire GKN shaft, not just the CV joints. If/when it becomes necessary on my G, that's the way I would go; although MB shaft from the right discounting dealer is not too much more expensive than the GKN.
Yes, I only paid about $100 more for the genuine MB shaft. I would have gone with the GKN version from ET if it had been in stock at the time. |
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| RE: A revisit surprise to me!
Floobydust - 12/28/2014 9:02 AM DUTCH - 12/28/2014 6:52 AM Have you considered replacing the rear engine mount - the one that supports the tail of the tranny? If that is worn and out of line, that could be another source. When I did this on my 280GE, there was a major improvement. Thanks for the suggestion, but I've already done that and it made no difference. In fact, at this point I have replaced every rubber interface on the entire drive train and suspension. The truck drives like a dream except for that vibration. Just before Christmas I did one last "maximum perturbation" on the transfer case where I flipped the homokientic shaft front to back and rotated in 180 degrees in the coupling flanges. The idea was to see if anything changed related to the vibration and it didn't. So at this point I can only conclude that there is something amiss in the TC itself. Thanks again everyone. Another update. This one comes with a slight vibration consideration, "Floobydust".... I thought I'd try to retighten the clamps in place, for now... Before I waste any more time on that idea, I needed to remove the small clamps and load the estimated amount of lost CV grease. I was able to slide a 1/4" poly tube/attached to my mini grease gun, between the rubber and the shaft. Now call around for new clamps, nothing available locally, so I decide to spread the old clamps and reuse them. Now onto the large clamps. I can reach the clamp ears with the pincers. I give the first clamp, "all I have", snap goes me pincers!!! Off to HD and buy a nail puller/pincer. I managed to exert much more force than before. With fingers crossed, I head for the highway. 90 MPH should give me some idea. One clamp is holding, the other is still weeping ever so slightly. I'll give it another shot soon. In the process of replacing the shaft and the TC mounts, I've developed a slight vibration as well! Starts around 55 and beyond, it migrates to the steering at times. One thing I've noticed while swapping out the TC mounts, is all the play the M8 bolt holes allow. I did my best to seat the M8 washers exactly where they where, before I tightened the thru mount bolts. Even the thru bolts have play enough to raise the TC as much as a 3/16" above resting. The exact placement of the TC, in relation to perpendicular shafts, seems to be somewhat hit or miss to me. I'm going to set up a pair of lasers on the drive shafts, hoping to see if they are perpendicular to the TC, or at least parallel to each other. More soon. |
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Floobydust
Veteran
Date registered: Mar 2014
Location: Massachusetts, USA
Vehicle(s): 1995 E320 Cabrio, 2003 G500, 2000 SL500, 1980 TR8
Posts: 284
| RE: A revisit surprise to me!
NHDave - 1/6/2015 7:34 AM
In the process of replacing the shaft and the TC mounts, I've developed a slight vibration as well! Starts around 55 and beyond, it migrates to the steering at times.
One thing I've noticed while swapping out the TC mounts, is all the play the M8 bolt holes allow. I did my best to seat the M8 washers exactly where they where, before I tightened the thru mount bolts. Even the thru bolts have play enough to raise the TC as much as a 3/16" above resting. The exact placement of the TC, in relation to perpendicular shafts, seems to be somewhat hit or miss to me. I'm going to set up a pair of lasers on the drive shafts, hoping to see if they are perpendicular to the TC, or at least parallel to each other.
Welcome to my world! If you look carefully you will see that the left rear and front TC mount to chassis holes are slotted whereas the right rear are drilled round. This seems more like it's set up to account for manufacturing tolerances that setting an alignment as I think in the later case, all three sets would be slotted. I read on some thread somewhere in the ether that one should drive the truck with the 6 M8 bolts slightly loose to let the TC find "its happy spot", then coast gently to a stop and tighten them. I'm not sure how much credence to put in that, but that is what I read. I have tried multiple positions on my TC and none seem any better than any other. |
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 465
| RE: Transfer Case rubber mounts
I'm not surprised you've noticed this as well. The idea or driving around with lose bolts seems odd, then again, the poster must have been chasing something to warrant it? If you do pull the trigger on another TC, it'll be interesting dismantling the old. Perhaps you would like some company when and if you choose to do so? Best of luck |
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Floobydust
Veteran
Date registered: Mar 2014
Location: Massachusetts, USA
Vehicle(s): 1995 E320 Cabrio, 2003 G500, 2000 SL500, 1980 TR8
Posts: 284
| RE: Transfer Case rubber mounts
NHDave - 1/7/2015 8:24 AM
If you do pull the trigger on another TC, it'll be interesting dismantling the old. Perhaps you would like some company when and if you choose to do so? Best of luck
I appreciate the offer of company, but unfortunately I got stuck traveling for work over the next two weeks, so I won't be able to do anything until afterward. I will repost when I am back. BTW, a lot of nice G Wagens here in the UK.
Edited by Floobydust 1/10/2015 3:47 AM
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