Hi Folks a little advise needed.

I needed a new transfer box due to being stuck in diff lock, the only 1 i've being able to get is an alleged td5 one, My motor is a 97 300tdi.

My question to all them with the knowledge is, will i have any problems fitting it?

I've already removed the old box and have them sat side by side the only things I've noticed is - there is no speedo sensor/transducer and no mounting for 1 on the td5, it has an extra switch to the original which i think is the high/low selector switch? the front prop fitting was missing.

Will i have to swap the whole unit that the speedo fits into? im guessing i just ignore the extra switch? will my front prop fixing fit? and is there any other things i need to look out for?

Cheers in advance
Crofty.

does it have diff lock selector spigot poking out of front housing ,speedo housing can be swapped *youd need to fit speedo worm too)but there is a raised surface on housing which pushes rear diff bearing in the housing these vary quite a lot and will badly effect diff bearing preload if not the same as was or made so 4xtra switch is hi/low sender you could just leave as is

Are you 100% the box is stuck in difflock and its not just the selector mechanism?

Glb8686 said:

Are you 100% the box is stuck in difflock and its not just the selector mechanism?

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Yes, I'd had another thread running on a ongoing problem i had, which turned out to be the fact i'd being driving around in diff lock.

Crofty.

jamesmartin said:

does it have diff lock selector spigot poking out of front housing ,speedo housing can be swapped *youd need to fit speedo worm too)but there is a raised surface on housing which pushes rear diff bearing in the housing these vary quite a lot and will badly effect diff bearing preload if not the same as was or made so 4xtra switch is hi/low sender you could just leave as is

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Yes the diff lock selector spigot is there, by speedo worm do you mean the internal bits? where and how do i check for the said raised surface?

Cheers Crofty

you will see it when you pull a housing off ,it pushes/seats bearing ,if you think 3 thou preload is what your after 10 thou difference is a lot and they often differ much more you can check by removing intermediate gear and rotating diff assembly to feel tightness

jamesmartin said:

you will see it when you pull a housing off ,it pushes/seats bearing ,if you think 3 thou preload is what your after 10 thou difference is a lot and they often differ much more you can check by removing intermediate gear and rotating diff assembly to feel tightness

Click to expand...

Cheers Martin,

not quite sure how to do the latter part but will give it a go!!

Crofty