4matic transfer case question
 

On the 1991 era 300 TE's, (124) the very expensive 4 matic transfer case had to be replaced between 70 - 100 K miles because of aluminum piston wear and internal leakage. I understand that they were rebuilt using steel pistons. Question: Will the rebuilt transfer case now last much longer and be normally reliable?

logically you would think the xfer case would last longer with the mod.but i recommend shutting down the 4matic operation during that part of the year when you would not use it.this can be accompished by generating a fault code in the 4matic computer effectively shutting it down.this is most easily acheived by flipping the test/run valve under the hood to the test position with the engine running and then flipping it back again.to restore 4matic operation just remove battery power for a short interval.this will reset the computer

I believe the new transfer case will last longer than the original, because the steel will not fail as rapidly as the aluminum does on the originals. As for turning off the 4matic system, I wouldn't recommend that, (though I'm not a tech), because there are other systems, such as the self-leveling suspension that are intertwined with the 4matic system, so to disconnect one is to disconnect them all. If you do a search regarding the 4matic, you will find that this subject, and disconnecting the system vs. not, has been discussed previously.
As I am sure you well know, when the 4matic sytem is working, there is no better 2/4wd system out there, even now, ten plus years later. The 4matics do have their headaches, but they are worth it in snow country!

1962 MB 220SEb "Fintail" Sedan
1992 MB 300TE 4matic Wagon
1995 Subaru Legacy AWD Wagon

1991 4matic Wagon
 

Does anyone know where I can purchase a rebuilt transfer case for a 1991 MB 4Matic wagon.
Thanks

Simply Google: mercedes rebuilt transfer case and you will get a lot of hits. There is even one site called www.transfercases.com I know absolutely nothing about any of these vendors, so good luck.