What's inside Mercedes G W463 transfer case ?

In this video I disassemble Mercedes G (W463) transfer case to investigate how things work inside
W460 and W461 have no differential mechanism inside
High gear ratio: 1.00
Low gear ratio: 2.16
W463 got transfer cases with 3rd differential and locking mechanism
Early W463 (with engines like OM603) have manual high/low gear selection
High gear ratio: 1.05
Low gear ratio: 2.16
Later W463 (with engines like OM603/OM606) have manual high/low gear selection
High gear ratio: 0.87
Low gear ratio: 2.16
And more later W463 got this electric motor for high/low gear selection
High gear ratio: 0.87
Low gear ratio: 2.16
00:00 Intro
00:40 Weighting
00:53 Transfer case overview
01:54 Outer parts disassembly
03:32 Removing back cover
05:22 High/Low selector mechanism
06:04 Gears working principle
06:56 Differential locking mechanism

[@alexcontt4669]

Excellent video very Educative Thanks!!

[@MManuu]

I was waiting to see some sand inside.

[@paulryan522]

This is great, thank you for making the video and sharing it with us! :-)

[@MercedesOffRoadClub]

Glad you enjoyed it!

[@sergsam6316]

Hello, what type or Fluid/oil the transfer case uses?

[@MercedesOffRoadClub]

80W90 GL4 (MB 235.1)

[@alvaropelado]

What a great video!!!! Thanks a lot for sharing. I can wait to see more of your videos. I have a g500 (2017) i bought with 200.000 kms. Does it use the same transfer case? What opinion do you have on the g500 (2017)? The main use we do for it is traveling and overlanding.

[@MercedesOffRoadClub]

Thank You for the comment!! I appreciate it! Your g500 has the same TC and I think thats very good version for what you want to do. It is V8 so as an overlander I would consider additional fuel tank if you plan long trips. Each G if properly prepared is good for overlanding. There is a lot of options and I think it is the most important what you like and fit G for your liking. In our local G owners society there is one guy that has never enough of HP and there is one with his good old W461 95HP (which he loves) and sometimes I think its too much for him so go what you like and what suits you best, thats the most important. Cheers!

[@rifienih]

Hi, im Rifie from Indonesia. This video is really help me find out how the center locker on my W463 work. But I have a problem here and maybe you can help me. My TC has some issue when I engage the center locker and off road in heavy terrain. There are a grinding noise and all four wheels not moving. If I stop push the throttle, grinding noise gone and the wheels start moving again.. I think the center locker act not locking properly. Any suggestion? Pls help 😢

[@MercedesOffRoadClub]

Hello Rifie. Grinding sound is not good. First I would investigate grinding source. I would lift entire G on some sort of column jack in garage, so that all wheels hang free, start engine and on first gear I would engage all diff locks one by one and listen for grinding where does it come from. Where ever grainding comes from you have to take this part out from G and disassemble anyway. Good luck.

[@rifienih]

I already try this, but if there is no load the grinding noise will not appear. And it just works fine. Grinding noise only when there is any heavy load just like when im stuck in mud. Any thoughts?

[@MercedesOffRoadClub]

This can be excessive bearing or gear (tooth) wear, but this noise is more like hauling and it is often inside axles - ring and pinion gear wear. It is hard to tell through the comments, maybe if you make video and post it with sound ??

[@filipghermanionut3732]

do you know somebody who swapped an om605 on a w460/463?

[@MercedesOffRoadClub]

No, sorry mate

[@MManuu]

I was waiting to see some sand inside.