Help, transfer case stuck

[tflda29]

Hello,

I have an M class w164 and the problem with the transfer box chain. I took the cover off the transfer case whilst it was on the car and replaced the chain but can’t get the cover back onto the case?

The cover stops about an inch short of the mating surfaces. What am I doing wrong?
Any help greatly appreciated.

Thanks
Trevor

 

[Uncle Benz]

I always take the transfer box off and do the job on the bench. It sounds like you don’t have a spline lined up somewhere, but without seeing it, difficult to say

 

[tflda29]

I always take the transfer box off and do the job on the bench. It sounds like you don’t have a spline lined up somewhere, but without seeing it, difficult to say

Thanks fir the reply Uncle Benz. Yes wish I had done that now but heard it was a nightmare to get out with two top bolts,hard to reach, so thought this would be a better option. I guess it’s not.

 

[Uncle Benz]

The cover has two splines that need to go onto the long shaft. The centre differential is in the cover you have removed. From memory, I twist the input shaft from the gearbox side until they slip into place. That’s going to be difficult with the transfer box still mounted to the gearbox.

 

[tflda29]

The cover has two splines that need to go onto the long shaft. The centre differential is in the cover you have removed. From memory, I twist the input shaft from the gearbox side until they slip into place. That’s going to be difficult with the transfer box still mounted to the gearbox.

Ah ok thanks for that. Looks like I will need to remove the rest of the transfer box. Ant tips on getting to the two top bolts?

 

[Uncle Benz]

Thinking now, if I remember correctly I use a short spanner and use a bar and a hammer to whack the end of it to loosen them.

 

[tflda29]

Thinking now, if I remember correctly I use a short spanner and use a bar and a hammer to whack the end of it to loosen them.

Thanks for you help I’ll give it a go.