Removal, installation and adjustment of actuator cylinders and components of the drive mechanism of the interwheel differential lock (Mercedes-Benz G-Class W463)

Front axle

Slave cylinder

1. Disconnect the hydraulic line from the slave cylinder assembly (1) - immediately plug the open ends of the line and the nipple assembly to prevent brake fluid from leaking.

2. Loosen the union nut and disconnect the electrical wiring.

3. Mark the installation position of the cylinder (1) relative to the bridge sleeve.

4. Loosen the mounting screws and remove the cylinder (1).

5. Install the cylinder in its regular place in accordance with the mounting marks applied during dismantling.



6. If the cylinder was disassembled (see Section Disassembly and assembly of the differential lock actuator cylinder) or replacing the differential lock components (see below), make the appropriate adjustment (see below).

7. Screw the pressure switch (2) into the cylinder (1) and tighten it to the initial torque.

8. Secure the cylinder (1) to the axle housing so that it remains possible to adjust its position.

9. Activate the cylinder and lock the cam clutch.

10. Adjust the position of the cylinder so that it rests against the coupling - when released, the cylinder should not move back under the force developed by the internal spring.

11. Tighten the cylinder to the required torque.

12. Tighten the pressure switch sensor completely.

13. Restore the original electrical wiring and hydraulic line connections.

14. Finally, bleed the air from the hydraulic circuit of the differential lock drive (see Section Bleeding air from the hydraulic circuit of the differential lock drive).

Lock engagement mechanism

1. Remove the slave cylinder (1) (see above).

2. Remove the hinge housing (3) together with the drive shaft (see Section Removal and installation front axle drive shafts).

3. Remove the differential assembly with the final drive driven gear (4) (see Section Removal and installation of interwheel differential assemblies with driven gears of final drives).

4. Remove the shift mechanism coupling (5) by slightly pulling it out together with the tube (6), and then unhooking it.

5. Remove the tube (6).

6. Remove the polyamide rings from the tube (6).

7. Carefully wipe the removed components; replace any faulty components.

8. Install the polyamide rings, having previously lubricated their rubbing surfaces.

9. Install the shift tube (6).

10. Hook the coupling (5) and push it together with the tube until the installation socket appears in the hole of the axle housing sleeve (see illustration below).

11. Install the differential assembly (4).

12. Install the hinge housing (3) together with the drive shaft (see Section Removal and installation of front axle drive shafts).

13. Install the slave cylinder (see above).

Rear axle

Slave cylinder

Adjusting the slave cylinder (1) of the rear axle differential lock drive



1. Disconnect the hydraulic line (4) from the slave cylinder assembly (3) - immediately seal the open ends of the line and the nipple assembly to prevent brake fluid from leaking.

2. Loosen the union nut (5) and disconnect the electrical wiring.

3. Mark the installation position of the cylinder (3) relative to the bridge sleeve.

4. Loosen the mounting screws and remove the cylinder (3).

5. Align the mounting socket (6) of the shift clutch with the center of the opening in the crankcase sleeve.

6. Install the cylinder (3) in its regular place in accordance with the mounting marks applied during dismantling - do not forget to replace the sealing gasket (1). Screw in the mounting bolts - the shift lever should fit into the installation socket of the tube, while it should be possible to adjust the position of the cylinder.

7. Apply hydraulic or pneumatic pressure to cause the cylinder to operate, then move it until it rests against the cam clutch (arrow) - while simultaneously turning the axle shafts until the differential lock is activated.



8. Tighten the mounting bolts to the required torque, then release the hydraulic/pneumatic pressure.

9. Turn the axle shafts to ensure that the differential lock is working properly.

10. Restore the original electrical wiring and hydraulic line connections.

11. Finally, bleed the air from the hydraulic circuit of the differential lock drive (see Section Bleeding air from the hydraulic circuit of the differential lock drive).

Lock engagement mechanism

The procedure is similar to that described above for the front axle, with the exception of the absence of the hinge housing.