Transfer box rebuild

Ian Maycock · Jul 6, 2017

Hi all , I've got an old transfer box in the garage so have decided to have a go at rebuilding it. Its a suffix E box it was off the stepsons 300 tdi the front bearing had collapsed , so I've part stripped it down and fetched the input gear out now I've become confused . I've been on the Ashcrofts website and was under the impression that the later boxes (after suffix A, B ) had a drilled input gear and no oil feed plate, were as mine has an oil feed plate and a undrilled input gear . Was the drilled input gear an upgrade part for when the original failed or have I got a cogged up box any help greatly appreciated >
cheers Ian

jamesmartin · Jul 6, 2017

drilled input gear wasnt fitted till mid to late 90s,count the teeth on the input teeth and report back

Ian Maycock · Jul 6, 2017

Its got 26 teeth James .

Al2O3 · Jul 7, 2017

jamesmartin said:
drilled input gear wasnt fitted till mid to late 90s,count the teeth on the input teeth and report back

Mint, it's like a military reconnaissance.

jamesmartin · Jul 7, 2017

Ian Maycock said:
Its got 26 teeth James .

theres 2 gears with 26 teeth early and later the later been ftc5089 (cross drilled) early one hasnt got a replacement with cross drilling
you can see difference in width of the teeth

frc5428

ftc5089

frc8917 is replaced by ftc5089 but frc5428 cant be

Ian Maycock · Jul 7, 2017

Cheers James so mines got frc8917 input gear in it which isn't drilled and I can replace it with ftc5089 which is drilled, already got one of them from ashcrofts for my other box but didn't need it. Do I leave the oil plate fitted or is it best to remove it ?
cheers Ian

jamesmartin · Jul 7, 2017

Ian Maycock said:
Cheers James so mines got frc8917 input gear in it which isn't drilled and I can replace it with ftc5089 which is drilled, already got one of them from ashcrofts for my other box but didn't need it. Do I leave the oil plate fitted or is it best to remove it ?
cheers Ian

if its got frc8917 you fit ftc5089 and remove oil thrower disc, when you get a new gear mesh it to the center teeth on intermediate gear and roll it around back forth etc to ensure it feels to mesh properly

Ian Maycock · Jul 7, 2017

Cheers James will do .

Transfer box rebuild

Ian Maycock

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jamesmartin

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Ian Maycock

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Al2O3

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jamesmartin

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Ian Maycock

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jamesmartin

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Ian Maycock

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