Puma 130 Transfer case issue(s)

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Originally Posted by Tote

Thanks for that, I wasn't sure if it was like a Quaife diff where it wont lock up unless there is enough torque on both sides and Google wasn't forthcoming with an answer.


Regards,
Tote

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It's exactly the same as the Quaife, they are a knock off, but the preload from the bellville washers between the side gears makes it pretty stiff when new.
Some older ATB's had a habit of cracking bellville's in use, though, so they can lose their preload.

As an aside I'm taking a precautionary approach and replacing the stock Chinese belvilles with Schnorr bellville washers when assembling the diff assemblies.

This video explains the ATB quite well: LT230 ATB Vs Factory Centre Diff - YouTube

I pulled the transfer case today, about 5 hours work made slower by not having done one before and having to figure out how wiring clips and other bits and pieces came undone.

There was a bit of material on the drain plug but no gears came out with the oil so that's a good start.

Attachment 185470

When I got it out there was some corrosion on the spud shaft although it doesn't look too bad. Its also been lubricated from the factory as evidenced by the lubricant sprayed around the inside of the case.

Attachment 185471

Attachment 185472

Some lessons learned:

The plate with the 30mm spigot for the trolley jack is a great idea if you can lift the vehicle high enough to get the transfer case out from under the chassis rail. SWMBO and I had to lift it off the trolley jack under the vehicle and slide it out.
You don't need to pull the floor plate from under the console to get the transfer case out.
Taking the handbrake assembly off is pretty easy and if you undo the lever in the cab you don't have to worry about detaching the cable when removing the entire drum assembly from the transfer case.

Regards,
Tote

D1 transfer case in today and it all seems to work. A couple more lessons.
You can save yourself the trouble of swapping the top housing for the range selector if you have a mounting ball for a strut lying around. The ones I had were the same as the knob that the rod from the transfer lever mounts to, bolt it on to the lever and you are good.
I needed to swap the speedo gear over as well because the D1 unit has a smaller diameter shaft for the sensor to slide into. Despite the doom and gloom on the interwebs both gears came out easily.
I'm living without a diff lock indicator and a low range switch for now.

Next task when I get a chance have a look at the original transfer case and order some rebuild bits, but at least I don't have to drive a jeep out to the farm, SWMBO's project CJ10 has been doing farm duties (slowly)

Regards,
Tote