Description
Factory Mercedes G Class W460 Workshop Manual (1986–1992)
This official Mercedes-Benz dealer software delivers complete factory-level service and repair coverage for every G Class W460 variant sold in the US and worldwide between 1986 and 1992, spanning petrol and diesel powertrains across short and long wheelbase body styles.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | 2.0L M 102.964 E20 (200 GE), 2.3L M 115.973 (230 G / 230 GE), 2.6L M 115 Brabus (230 GE 2.6), 2.8L M 110.994 (280 GE / 280 GE AMG) |
| Diesel | 2.4L OM 616 (240 GD), 2.5L OM 602 (250 GD), 3.0L OM 617 (300 GD) |
| Transmissions | 4-speed manual, 5-speed manual, 4-speed automatic 720.1 (W4A 018) |
| Drive | 4WD (part-time); SWB and LWB chassis; left- and right-hand drive |
| Model Years | 1986, 1987, 1988, 1989, 1990, 1991, 1992 |
| Badge Twins | Puch G (Austrian-market), Geländewagen military variants |
Common G Class W460 Repairs Covered
| System | Procedures |
|---|---|
| Transfer Case | Rebuild and seal replacement for the Verteilergetriebe VG 76/27; known for oil leaks at output shaft seals on high-mileage W460 units |
| OM617 Diesel Injection Pump | Bosch injection pump timing adjustment, governor servicing, and cold-start advance repair — a frequent maintenance item on 300 GD models |
| Front Axle / Swivel Hubs | Swivel hub bearing and seal overhaul; grease repacking procedures for Dana-style front axle assemblies prone to wear in off-road use |
| Cooling System | Radiator hose replacement, thermostat swap, and cooling fan clutch diagnosis — common overheating complaints on M110 six-cylinder variants |
Format & Delivery
Dealer software (Mercedes VMware Player Virtual Machine — NOT a PDF). Compatible with Windows XP through Windows 11, plus Mac and Linux. Instant download; lifetime re-downloads.
Frequently Asked Questions
Which W460 body styles does this software cover?
All W460 configurations are included: the standard station wagon (Kombi), short wheelbase soft-top, long wheelbase canvas-top, and panel van variants. Both civilian and military-specification chassis are covered within the 1986–1992 production window.
Is the Puch G / Geländewagen military version included?
Yes. The W460 platform underpins the Austrian-market Puch G and various military Geländewagen derivatives. Because they share the same chassis codes and drivetrain assemblies, this software covers their mechanical systems in full.
Are transfer case and front differential rebuild procedures included?
Comprehensive coverage is provided for the Verteilergetriebe VG 76/27 transfer case, front and rear differential assemblies, propeller shafts, and swivel hubs — including torque specs, special tool requirements, and step-by-step disassembly sequences.
What format is the manual?
This is professional OEM Mercedes-Benz dealer software delivered as a VMware Player Virtual Machine — it is NOT a PDF. The interactive platform includes searchable repair procedures, clickable wiring diagrams, component locators, and torque specification lookups, matching the tools used by authorized Mercedes dealerships.
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