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Transfer box reconditioning - DIY?


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I'm fairly handy with the spanners etc. it's looking like my gearbox is going to have to come off, so I'm thinking I might recon my spare transfer box at the same time to replace the leaky one on there. Is there anything massivley challenging about the job? Are any special tools required?

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I've rebuilt one in the back of a 110..... Dead easy. Hardest bit was keeping my hands clean to eat my chips.

All the info is in the workshop manual and iirc you need spanners and bearing pullers and that's it.

There is a shim in the front output housing that might need changing but I doubt, and there is also a shim behind the front bearing of the input gear.

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Easy have done two recently. Access to a large vice, some brass drifts and a dishwasher also helps!! If you get the overhaul kits they come with all the new stake nuts, seals, bearings, crush tubes diff lock switch etc. Pay extra to get Corteco seals and Timken bearings.

Toby

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That all sounds reassuring!

What's the general thoughts with the intermediate shaft where it sits in the txb case? Just replace the o rings there, or is it really a common problem for the hole itself to wear and need a steel insert?

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Or me, or Dave on my mill!

I've studied the manuals and come to the conclusion the t'box is that easy it isn't worth sending to a specialist, the LT77 on the other hand is. Plus although it's heavy, it's not a major job to get the t'box off if it fails, whereas the LT is much more of a job.

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A further question on this.

With my current transfer box, i believe the only issue that it has it leaking from the intermediate shaft o rings. Now, i think there are two in there - one in the case and one on the shaft. With the box off of the vehicle, can i remove the intermediate shaft, replace the o rings and reset the preload on it (with a new crush spacer) without dismantling anything else? I have a feeling that the gears that the intermediate shaft mesh with will need to be removed to do this so the answer is probably no?

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But can I set the preload properly on reassembly? When I got this box, it had a loose stake but on the intermediate shaft so it'd be nice to make sure it's set properly.

I'm probably cutting corners and should just rebuild the box properly!

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I may take you up on that David :)

I could just refit my old box, it leaks in the same way the newer one does. Annoying really as the person who sold me the current one assured me it was a leak free perfect box. (They aren't on here or other fora much these days...)

What makes the td5 transfer box better than my original from 1989?

My current thinking is drop the lot this weekend. Recon one of the TXBs I have in the evenings next week. Decide what an earth to do about the main gearbox (repair or replace) and refit the lot next weekend.

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Yep - my understanding was that it is the Q boxes that were quieter. I run an overdrive on my 110 - i thought the Q boxes had the gear angles cut such that the OD couldn't be used on them? Or, am i thinking of something else?

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To save starting a new topic I have a couple of related questions....

I have a number of transfer boxes on the floor including a late TD5 disco one without the difflock mechanism. I am hoping to rebuilt a good box using the internals from the TD5 box (Q gears???) into an earlier case with a difflock fitted. Is this possible to do?

This will be to replace current box on the 110 which is starting to leak quite badly from around the slaked nut. Is there a temporary fix for this without removing the box from the car?

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