Transfer box removal next week

This is going to take place next week I have read some excellent posts on the forum and have planned it out as per the excellent write-ups I've looked at. Disco is up on 4x ramps, fully chocked & I've been under & dowsed every nut, bolt & fastening in shock-unlock ready. Exhaust off, props off, handbrake drum off and that's as far as I've got (mum coming up over weekend so removal put back ) I can see all 6 nuts/bolts that hold it on & the offside bracket to the chassis. I've also con-cocked a kind of cradle on the top of my trolly jack as I don't fancy another slipped disc or 2 trying to lift it. My only question is......Regarding the diff lock and Hi/Lo linkage - Can you get at it from underneath or do you have to remove the centre console???? From what I can see access looks very limited????

Reason for it coming off is that both front & rear output are leaking & there's play in the input / output behind the PTO cover.

Any tips would be appreciated.

Jasonmichael said:

This is going to take place next week I have read some excellent posts on the forum and have planned it out as per the excellent write-ups I've looked at. Disco is up on 4x ramps, fully chocked & I've been under & dowsed every nut, bolt & fastening in shock-unlock ready. Exhaust off, props off, handbrake drum off and that's as far as I've got (mum coming up over weekend so removal put back ) I can see all 6 nuts/bolts that hold it on & the offside bracket to the chassis. I've also con-cocked a kind of cradle on the top of my trolly jack as I don't fancy another slipped disc or 2 trying to lift it. My only question is......Regarding the diff lock and Hi/Lo linkage - Can you get at it from underneath or do you have to remove the centre console???? From what I can see access looks very limited????

Reason for it coming off is that both front & rear output are leaking & there's play in the input / output behind the PTO cover.

Any tips would be appreciated.

Click to expand...

In my opinion you would be wise to remove the centre console and remove the rubber insert beneath it, this involves drilling out the pop rivets that fasten it in place, removal of these bits gives good access to the top fasteners holding the transfer case to the rear of the main gearbox.
I have had the transfer case out of my D1 manual, but I made up a small gantry that sits on the front floor in frount of the seats with the seats pushed all the way back, my gantry connected to the transfer case by one bolt and bracket hanging from a short piece of 1/4" link steel chain weldeded to the end of a 16mm threaded rod that passes through a hole in the gantry beam, the nut sitting on a thrust bearing. This device has allowed me to single handedly remove a whole gearbox/transfer case assembly on one occasion and the above mentioned transfer case only on another occasion with consumate ease, working mainly from above inside the cabin after all fasteners are removed from beneath. The threaded rod and nut gives absolute control for removal and for repositioning for replacement, your idea with a frame on a jack is also going to give good control, but means you will need to be under the vehicle a lot with a top heavy load.
I suggest that whilst the transfer case is out that you replace the intermediate shaft sealing "o" rings, the input shaft seals and check the spline condition of the input gear which, in some earlier gearboxes were prone to heavy wear in the spline area in both gear and gearbox output shaft, it is not so much a problem in newer boxes, but, as you think yours may have some issue in that area, maybe the modified version of the input gear is required.
On my transfer box the replacement of the intermediate shaft seals and clearing out of the breather tubes for transfer and main box cured all the transmission oil leaks perfectly.

I think that the rubber diaphragm is no longer available? seen that somewhere.

The transfer box has a long stud from the R380 rear housing that is has to be slid off from, but it's useful when reassembling to keep things in line.

Peter

Thanks for your replies, Looks like I might have 'fun' over the next couple of days