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| Rickydodah Member Since: 14 Jul 2014 Location: East Sussex Posts: 1091  |
Yes the transfer box needs to be drained before removal as some of the retaining bolts are threaded through into the box. Are you repairing yourself? The coupling on mine was
 tight. Good luck  I started with nothing and still have most of it left! |
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2nd May 2016 9:36pm |
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| Pickles Member Since: 26 May 2013 Location: Melbourne Posts: 3781  
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I know the feeling Darren, happened to us a couple of months ago,...I hope you weren't far from home.
Pickles. |
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2nd May 2016 10:32pm |
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| nitram17 Member Since: 08 Jun 2014 Location: newcastle Posts: 2261 |
Is it repairable by one person? ie is it heavy and do you need any special tools? Do you need to replace any seals.. its just i am a bit ocd when it comes to future proofing ,,that is i intend to create my own database of HOW TO ....and short cuts and i will buy a few odds and sods of parts, tools seal kits "just in case". |
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3rd May 2016 11:21am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17337  
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Yes.
Yes. A strong person can lift the transfer box down and up again afterwards, but I really don't recomment it. You can use a jack (ideally a transmission jack) to make the job significantly safer. use of a jack also greatly reduces the risk of damaging the transfer box input seal when refitting. Don't take risks with the transfer box, it is heavy enough to kill you if you drop it on the wrong part of your body.
You can do it without but there is a couple which help a lot. Most usefully, there is a tool to hold the part of the joint which is bolted to the gearbox output spigot when you undo the (very tight and threadlocked) bolt which retains it. It looks like this: 
You can improvise this tool, but it is fairly complex to make. You can use a windy gun and not use the tool, but I personally wouldn't do this since you are putting faily massive torque loadings back through the 'box, and the impact action won't be doing your gears any particular favours. It is also (sadly) an expensive tool to buy. The outher tool which helps a lot but is easy to improvise is a wedge-shaped thing to fit between the sloping bottom of the transfer box and the horizontal top of the jack. You will also need a large torque wrench to do up the retaining bolt aferwards. Whilst you have the thing in pieces it is advisable to check and if necessary replace the gearbox output shaft seal, the transfer box input shaft seal, and possibly the transfer box rear output flange seal (the one that leaks oil into the handbrake at the slightest opportunity). You will of course need the gearbox output adaptotor shaft complete with coupling, and seal, but the seal cover should be re-usable (it is only pennies to buy a new one though). To do the job, in essence, you need to:- - Disconect the propshafts from the transfer box. - Remove the handbrake assembly complete fro the transfer box - Drain the transfer box - Disconnect the difflock and high/low linkages from the transfer box, along with all electrical connections - Support the transfer box and remove the gearbox mount whcih is attached to it - remove the transfer box from the main gearbox. The main gearbox rear extension housing can then be removed, exposing the carnage within. Last edited by blackwolf on 3rd May 2016 1:25pm. Edited 1 time in total |
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3rd May 2016 12:02pm |
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| Rickydodah Member Since: 14 Jul 2014 Location: East Sussex Posts: 1091 |
I would advocate the use of some threaded bar or studs screwed into the extension housing to enable the transfer box to be slid into position avoiding damaging the seal. I concur with Blackwolf the box is heavy and if you're lying on your back then you head is directly under it if you decide to manually lift it in and out.
I started with nothing and still have most of it left! |
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3rd May 2016 12:14pm |
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| DarrenJ Member Since: 07 May 2012 Location: North Beds Posts: 312 
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Thank you for the info. I will, all being well, strip out on Saturday and intend on using a trolley jack to support the transfer box out.
Fingers crossed it goes well... Darren |
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4th May 2016 9:09pm |
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| DarrenJ Member Since: 07 May 2012 Location: North Beds Posts: 312
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Removed the transfer box, I can confirm it is heavy!!
I have definitely been struck with the intermediate shaft failure, dry as a bone and splines all worn away. I just need to remove the gearbox extension and the gearbox output shaft adaptor now... Darren |
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8th May 2016 8:26pm |
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| nitram17 Member Since: 08 Jun 2014 Location: newcastle Posts: 2261 |
Any photos Darren?
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8th May 2016 11:32pm |
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