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goingbush
29th November 2016, 12:35 AM
Have my Transfer case out to fix some 'minor' Issues and found a solution to the catastrophic failure in the Low Range cluster. Iveco continue to throw $15,000 transfer cases at them under warranty.

Mine is out of warranty now , I made a simple alloy block to catch on the ends of the circlip & stop it moving about or coming adrift.

Its an interesting TC, worth a look

https://youtu.be/FN5hAZsQa7U

Graeme
29th November 2016, 06:46 AM
The clip appears undersized, too light/flexible to stay fitted but perhaps would require a wider or deeper groove to take a heavier version.

goingbush
29th November 2016, 07:54 AM
The clip appears undersized, too light/flexible to stay fitted but perhaps would require a wider or deeper groove to take a heavier version.

Correct, When I inspected mine , There was only 0.5mm of c-clip inside the groove one end was out of the groove, as in the very first image of the video, i could just pry it up with a screwdriver.

Iveco say they have revised the Transfer case by making the groove deeper, which if true, is a wasted effort as the new circlip is one and the same.

How can a company keep throwing $15,000 Transfer cases at these trucks when an engineering solution is so simple ??

https://www.aulro.com/afvb/images/imported/2016/11/72.jpg

goingbush
29th November 2016, 08:31 AM
couple of photos showing the fix

Decking the "circlip lock" face,

https://www.aulro.com/afvb/images/imported/2016/11/63.jpg
https://www.aulro.com/afvb/images/imported/2016/11/64.jpg


Added inspection port for endoscope whilst i'm at it

https://www.aulro.com/afvb/images/imported/2016/11/65.jpg

My circlip lock has a tang that sits in the groove, ends of circlip sit against the lock so they can not float about and loosen. There is a small gap to allow for thermal expansion of the circlip.

https://www.aulro.com/afvb/images/imported/2016/11/66.jpg

https://www.aulro.com/afvb/images/imported/2016/11/67.jpg

https://www.aulro.com/afvb/images/imported/2016/11/68.jpg

https://www.aulro.com/afvb/images/imported/2016/11/69.jpg

showing clearance of high / low range selector fork .

https://www.aulro.com/afvb/images/imported/2016/11/70.jpg

https://www.aulro.com/afvb/images/imported/2016/11/71.jpg

spudboy
29th November 2016, 08:39 AM
You're not afraid to take on major mods are you?! Good work.

goingbush
29th November 2016, 09:04 AM
You're not afraid to take on major mods are you?! Good work.

what could possibly go wrong :angel:


Its out of warranty, Iveco can't fix them once they let go.
My plan was to install a divorced LT230 with Ashcrofts ATB and underdrive,
so I thought "what the hell, if I can't fix it I still have the LT230 option"

but this SCAM TC is pretty solid, its just got some pieces that are not thought out too well. Like the Oil seals , the Selector rods just have o-rings in the front housing , they are hardened , cracked and leaky , and TC needs full disassembly to replace a $1.00 o-ring !!! , so I'll put some proper seals on the front of the case, stupid little things like that .

plenty of meat on front of TC to put external oil wiper seals

https://www.aulro.com/afvb/images/imported/2016/11/61.jpg

And the input flange oil seal is on the inside of the input housing ???? Bizarre, I'll be making a new housing with the seal on the outside

- what were they thinking ??

https://www.aulro.com/afvb/images/imported/2016/11/62.jpg

Graeme
29th November 2016, 01:00 PM
Is there enough material thickness on the original flange to enlarge the seal diameter leaving an internal lip? You could just remove the lip and fix the seal with appropriate seal retaining compound or possibly provide an external retaining plate fixed with 3 screws.

goingbush
29th November 2016, 01:06 PM
Is there enough material thickness on the original flange to enlarge the seal diameter leaving an internal lip? You could just remove the lip and fix the seal with appropriate seal retaining compound or possibly provide an external retaining plate fixed with 3 screws.

yes, have removed lip , but having trouble seating seal flat , you just gave me an idea though, I'll remove some material and insert a sleeve with a collar for the seal to fit against. QED

Hall
30th November 2016, 04:10 PM
Or you could put a circlip at the correct depth, thus making a square shoulder.
Cheers Hall

Blknight.aus
30th November 2016, 04:45 PM
Nice work..

If the circlip originally fitted was the correct one but was put in an undersized grove it wouldnt sit in and be under too much pressure.

in theory (or more accurately as I prefer to see them) For an external gripping Circlip (like yours) the OD of the groove should be just a fraction larger than the OD of the circlip when fully released and the shoulder of the groove should be in the 1/2-2/3 of the clips width. and for an internal gripping one a firmish fit in the range of the clips relaxed ID+ 1/4-1/3 the clips material thickness. and the same groove depth.

I wonder if the Tcases are suffering because some engineer had a numpty day and specced up the dimensions of the groove on the wrong set of tolerances?

mox
2nd December 2016, 05:35 PM
I remember a while ago a story was posted on probably several 4WD forums about a transfer case in an Iveco Daily under warranty failing about midway along the Canning Stock Route. Apparently a message about it got out via satphone on a Thursday evening. Iveco Care in Perth quickly decided that towing or carting the disabled vehicle out was not practicable. They pulled transfer case out of a new one and sent it by fast freight to Mt Newman. Two local mechanics made what I recall was a 9.5 hour trip , removed "blown up" case and installed new one. Vehicle apparently driveable again on Sunday morning.


Maybe someone could comment about whether the problem was as described above. Also link to somewhere story is still posted. In the meantime, probably Iveco has gained the odd extra new vehicle sale with this demonstration of quickly fixing a major warranty problem. Meanwhile, with what this one cost them, most likely modified parts to fix the problem should have become a high priority. Then installing them before more failures occur would most likely save the company repair costs and lowering reputation of its product for reliability.

goingbush
2nd December 2016, 08:49 PM
Hi mox, at least 20 Iveco Daily transfer case have blown, that I know about, Factor in the people who are not on social media / internet forums etc, or the people unwilling to announce to the world their pride & joy let them down, Say double that figure.

The story you refer to on the CSR was published in Ivecos own trade journal like a feather in their cap for good service. And yes it was the exact circlip that failed.

I have the story on my webpage, with permission from the bloke that wrote it.

www.goingbush.com/iveco4.html

Iveco Australia, just don't give a **** !! Im probably going to be the bunny doing this Mod, Iveco are not interested, Ive got a line of owners that want it done at the risk of voiding their warranty. Thats Irony !!

roverrescue
2nd December 2016, 09:48 PM
Nice mod goingbish
I presume you chose a retaining option over machining a deeper wider groove because of clip availability?

Steve

goingbush
3rd December 2016, 08:02 AM
Yes Steve as Blknight suggested, more appropriate groove & better circlip selection would be ideal but the length of 'knee' on my mill did not allow a full rotation of Transfer case when mounted on the rotary table.

I had planned on making a full collar with ears to bolt down over the thrust plate, with or without circlip , but this simple 'circlip lock' seemed a more elegant solution.

The Transfer case rear cover can be removed from Case whilst still mounted in truck, Only the rear prop and TC mount crossmember need to be undone, so it could be a straightforward mod .

Iveco Aust mgmnt have told me it takes a Full 5 Years before any engineering changes are implemented into a production line, & that sounds about right . All MY2009 have an un-necessary RLPV in the rear ABS circuit . Logic defies its purpose, I removed mine early on & most people have theirs drilled out with the valve body still there to look original for 'insurance purposes' , It was deleted from production on the MY2014 model. )

goingbush
3rd December 2016, 08:15 AM
I also needed to make a Rotisserie to work on the TC , just need to build a fire pit now for a slow roast

https://youtu.be/ru64OllPo5U