is it possible to remove the transferbox without removing the gearbox?
Yes, the transfer box is at the rear so is quite easy to remove. Personally I can remove and refit the transfer box without the use of a crane and instead just lift it into position with some one inside to guide it into place as I slide it forward. It is however still heavy and not everyone will be able to do this. I am still young enough and strong enough to happily lay on my back under the vehicle with the box sat on my chest. I know this will not always be the case as I get older.
Here are a couple of guide on how to do the transfer box but it appears both have lost their pictures:
Link 1
Link 2
A basic list of small jobs you need to do is:
Remove the floor panels, gearbox tunnel and centre seat inspection hatch
Drain the transfer box
Remove both props
Remove the speedo cable
Remove the handbrake cable
Remove the hand brake drum and back plate (not sure if you need to do this have a disc conversion and the caliper does not allow it to move far enough back so needs to be removed)
Disconnect the diff lock switch wiring and breather pipe
Disconnect the gear and diff lock linkage (i undo the middle of the linkage for the gear selector at the threaded adjuster)
Support on a jack and remover the transfer box chassis mount
Remove all of the bolts holding it to the gearbox noting their position (they are not all the same)
Slide the box back and lower to the ground checking nothing is still attached
Refitting is just the reverse
Some people will remove the input gear before removing or refitting the box but I have never found this to be necessary.
