Transfer Case

Today's task was to take apart the transfer case and see why the gearbox was stuck in 4WD. As it turns out, it was simpy a long-term lack of lubrication, and so the parts were cleaned and re-lubricated, and then put back together. The box now works as it should, although the rear oil seal will need replacing, and I'll have to order the appropriate bolt for the 4WD selector lever.

Next views are of the case with the cover removed, and the parts cleaned and inspected. 4WD selector shaft has a little rust at the tip, but nothing excessive.

I used the old chassis as a workbench today. The dirt under the locking dog is just a small part of all the dirt removed from the outside of the casing today. Old gasket is an interesting colour....

Looking a little like a small missile, in part due to the 'wings' of the oil thrower half way along, the front output shaft was in good shape. Lighting makes it appear somewhat brown here, but it's not in real life!

Putting it together again for the test (minus the shaft-end dust cover), which was successful. The two bolts on the transfer shaft flange are there for a large wrench to grasp while undoing and redoing the nut.

Just a view of the clutch adjuster, put temporarily back on the bell housing until I get around to setting it correctly. Interesting to note that it appears that the starter motor shaft may have been making contact with the rear of its 'bump' in the housing.