Thread: Borg Warner rear output shaft easy to fix

OK I got motivated enough today to dismantle the rear output housing off the BW transfer that I bought off ebay in January.

As I suspected the output shaft was stripped which was a BIG surprise at 340KK . The vendor thought it was a broken chain but seeing the case was in one piece I doubted it.

So I thought I would practice on the old box before I had a go with mine.

I stripped the output housing down and removed the shaft and I couldn't believe how easy it was, as it took about an hour all up including modifying my circlip pliers to grab the humungous circlip. The only real problem is that you cannot get to one bolt ( the one behind the speedo drive) with a rattle gun and need to whack a ring spanner.

The bearing is held in by a circlip, so you do not have the angst with say a diff pinion, and the speedo drive is also retained with a circlip and stopped from turning by a ball bearing in a socket.

I now intend to put a new output shaft which I have into the ebay housing and swap it into my transfer. I will buy a new bearing which is a FAG 6207.C3 which appears to be quite common and cheap ($20 landed from Germany on Ebay or $27 from RS components.)

When I put the new shaft into the old case to see that nothing falls out of place when you pull the shaft, the old ebay box seemed quite tight with very little backlash, so I assume the chain is OK at 340K for a while yet. It was very easy to reinsert the shaft, with just light taps with the persuader.

The next step is to inspect my output shaft and probably regardless to replace it , unless it is perfect.

I guess the purpose of this post is that it seems quite easy to replace the shaft so it is probably worthwhile at about 200Kk to make absolutely sure you will not be stranded for another 200KK at least.

Really it seems to me that this and the VC are probably more easily fixable problems than the LT230 elongated holes etc.
Regards Philip A
Apologies to the person who I recall had a post called "For Philip A" with photos of the output shaft. I couldn't find it on search so raised a new thread.

I was looking at my Haynes Restoration Manual and found this drawing, which I thought I'd post up in case any of you chain-driven types might find it useful.