I recently picked up a W124 4matic transfer case as a spare for my 1990 300TE. I am looking for the overhaul manual and parts schematics so I can rebuilt it and have it ready for the inevitable. I already have the official MB 4Matic service manual, but it does not get into the detail of overhauling individual components that I need.

Any leads will be greatly appreciated!

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Peach Parts W124.128 User Group.

80 280SL
85 300SD
87 300TD
92 300D 2.5 Turbo
92 300TE 4Matic

I thought it might be of interest to some of you for me to share my transfer case removal instructions that I have developed during the process of removing the four extras I have sitting on my garage floor. I outlined each step with the tools I required to accomplish it. I have gotten the process down to about 1/2 hours. These instructions are intended to be quick, without regard to the condition of donor vehicle, and do not necessarily follow official Mercedes procedures.
4matic High Value Item Removal Instructions

(Note: these instructions are for parts removal from a salvage vehicle)

1. TRANSFER CASE
2. Engage parking brake.
3. Elevate Car from front or driver’s side
a. Ensure at least one rear tire can rotate
4. Cover ground -
a. Trunk liners or floor matts
5. Remove under engine shroud if present
a. 10 mm socket x6
6. Apply decreasing lubricant (brake cleaner) and penetrating lubricant to various fasteners
a. Particularly the exhaust downpipe
7. Remove various transfer case heat shields
a. 8mm socket
8. Remove entire exhaust
a. 13 mm socket
b. 3/8 long extension (2x)
c. Cable cutters for oxygen sensor
d. 13mm ratcheted wrench for exhaust support bolt
e. Channel locks for exhaust support nut
9. Remove drive shaft shield - bolt or pry bar.
a. 8 mm socket
10. Loosen drive shaft clamping nut
a. Extra large channel locks
b. Channel locks
11. Disconnect rear drive shaft at transfer case - Flex disc remains on drive shaft side
a. 15 mm socket (x3 bolts)
b. 3/8 extension
c. SHORT 17 mm wrench (x3 nuts)
12. Remove shifter connecting rod from transmission gear selector arm
a. Large/long flat head screwdriver
13. Move transmission to neutral
14. Disengage barking brake

CAUTION: VEHICLE WILL ROLL IF WHEELS ARE NOT BLOCKED

15. Rotate rear drive shaft as necessary to access flex disc bolts
a. Move transmission to park as necessary when removing bolts
16. Remove center drive shaft support
a. 13mm socket (x2 bolts)
17. Slide forward section of rear drive shaft towards rear & remove
18. Remove engine carrier
a. 17mm socket (x4 bolts)
b. 13mm socket (x3 bolts)

CAUTION: TRANSMISSION WILL TILT DOWN AT REAR


19. Tilt transmission downward - pivoting on engine mounts
a. Watch for speedometer cable, vacuum lines, etc . . . remover as necessary
20. Disconnect front drive shaft at transfer case - Flex disc remains on drive shaft
a. 15 mm wrench (x3 bolts)
b. 17 mm socket (x3 nuts)
c. Flat head screw driver for prying
21. Separate transmission / transfer case: WEIGHS APPROXIMATELY ___ POUNDS
a. 6 mm Allen head (x2 bolts)
b. 13 mm socket (x5 bolts)
c. Extension
d. Rubber mallet
22. Cut hydraulic oil line to front axle and central differential
a. Cable cutters
23. Place transmission in park
24. Remove ring gear retainer bolt
a. Hammer
b. Various punches - including fine point punch
c. 30 mm 12 point deep socket
d. ½ short extension
e. Breaker bar


25. Other 4Matic high value items

a. Front axles
i. Remove front center caps
(1) Small flat head screwdriver
ii. Remove front axle nuts
(1) Hammer
(2) Chisel/punch
(3) 30 mm 12 point socket
(4) ½ short extension
(5) Breaker bar
iii. Place support under lower control arm
(1) Weight of vehicle must compress front spring
(2) Remove wheel if necessary so that front axles can still rotate
iv. Remove inner joint housing
(1) 8 mm Allen head
(2) Mini 3/8 breaker bar
(3) Swivel extension
(4) 8 mm ball tip Allen head
(5) Long flathead screwdriver - insert into disk slots to hold axle from turning
v. Wire inner joint to axle to prevent separating
(1) 1-2' 12 or 14 gage wire (x2)
vi. Pull inside end of axle down and back, then pull outer end of axle out of hub
(1) Note: tricky


b. Steering angle sensor & steering wheel contact ring
i. Remove Driver’s Airbag
(1) CAUTION: DISCONNECT BATTERY
(2) CAUTION: DISCONNECT RED SRS PLUG
(a) Red plug under passenger forward footboard
(3) CAUTION: WAIT 10 MINUTES
(4) T25/T30
(5) ½ short extension
ii. Remove Steering wheel
(1) ½ to 3/8 adapter
(2) 3/8 10 mm Allen head
(3) Breaker bar
iii. Remove contact ring
(1) #1 phillips screwdriver
iv. Remove multi-switch/cruise control switch
(1) #2 phillips
v. Remove steering column shroud - to access cable
vi. Remove lower trim panel - to access plug
(1) Remove decorative cover trim
(a) Pull off headlight knob
(i) Plyers or channel locks
(b) Remove headlight switch retaining nut
(i) 24 mm socket
(c) While prying left of cover trim, pry to left
(2) Remove bolts
(a) 8 mm socket
vii. Cable cutter for any tie wraps


c. 4Matic hydraulic control module (located at fuel pump)
i. Unplug electronics under rear seat, passenger side
ii. Feed cable and plug through access hole
(1) small screw driver to pry grommet
iii. Remove fuel pump/ 4Matic control module under shield (if present)
iv. Remove plastic nuts supporting module
(1) 10 mm socket
(2) 3/8 medium extension
v. Remove hydraulic tubing
(1) Cable cutters






d. Brake Light Switch
i. Remove driver’s side lower trim panel
(1) Remove cover trim
(a) Pull off headlight knob
(i) Plyers or channel locks
(b) Remove headlight switch retaining nut
(i) 24 mm socket
(c) While prying left of cover trim, pry to left
(2) Remove bolts
(a) 8 mm socket

e. Hydraulic/Power Steering dual fluid pump
i. 13 mm socket
ii. Medium extension
iii. 13 mm wrench
iv. Vise grips or channel locks - to hold pulley
v. Cable cutters - to cut hoses

2. Other 4Matic unique items to consider
a. Front brake disks / pads
b. Lower control arm ball joints - 19mm socket /wrench (x4)
c. Tie Rods
d. 4Matic electronic control module
i. Behind battery
e. 4Matic ABS module
i. Behind battery
f. 4Matic Test switch
i. 90' - Hydraulic - on right inner fender wall
ii. 91'-93' - Electronic - adjacent to diagnostic ports by battery

3. Other 124 T items to consider
a. Self Leveling Suspension
i. Rear Shocks
ii. Nitrogen gas canisters
iii. SLS switch

4. Additional Tools and Supplies
a. Paper towels
b. Socket set, including Allen heads (12mm, 14mm, 17mm, etc . . .)
c. Ball joint fork
d. Tie down straps
e. Flashlight
f. Mirror
g. Handcleaner
h. Knuckle gloves
i. Nitril gloves
j. Zip lock bags for parts

__________________
http://i284.photobucket.com/albums/l...aman/Fleet.jpg

Peach Parts W124.128 User Group.

80 280SL
85 300SD
87 300TD
92 300D 2.5 Turbo
92 300TE 4Matic