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Thread: Transfer box problem..grrrr

  1. 26th May 2013, 03:40 PM #1
    Pierre
    Pierre is offline Wizard Silver Subscriber
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    Angry Transfer box problem..grrrr

    Now, I'm not God's gift to spanners, but I'm handy enough.

    No.3 son's beach truck is 95 V8 Disco auto. Transfer box started to clunk badly, so we've rebuilt another box, ready to go. OK, out with the original box, and finding that the spud shaft and transfer gear had destroyed (nearly) each other, a replacement spud shaft was procured and installed.

    Onwards to the transfer box installation. Up she goes, into the right spot on guide pins, blah, blah, and then...

    ....the box does not go all the way home. About 30mm not all the way home!!!

    On inspection, the spud shafts are the same (spline depths, lengths and ramps), the transfer gear has the same length and depth splines as the retired part.

    It appears that the spud shaft is sitting out 30mm from its correct position.

    The question.... What have I done incorrectly? Is there anything inside the extension housing which may foul the progress of the spud shaft to its correct position?

    Your inputs are invited.

    Pete
    Dizzie, 08 D3 TDV6 SE
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  2. 26th May 2013, 04:33 PM #2
    redrovertdi Guest
    Pull out the input gear from the transfer case[easy to do] and slide it on the output[spud] shaft of the box, when i was mix/matching for my auto conversion in my 300tdi 110 i had a similar problem and ended up turning the splines down on the spud shaft at the gearbox end as the ramps wouldnt let the input gear go all the way home, just my 2c
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  3. 27th May 2013, 08:45 AM #3
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    Homestar
    Homestar is offline Super Moderator & CA manager Subscriber
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    Had a similar issue when putting my TC onto a new gearbox - it sat out about that amount. I checked everything and everything appeared to be the same, so I gave it another go, and with a bit of help from an extra set of hands, it went on. I put it down to not having my tongue in the right position...

    I think they have to be dead square when fitting them or they jamb. Hope it is something similar to that. Keep us posted on how you go and what the issue was.

    Cheers - Gav.
    If you need to contact me please email homestarrunnerau@gmail.com - thanks - Gav.
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  4. 29th May 2013, 02:36 PM #4
    Pierre
    Pierre is offline Wizard Silver Subscriber
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    Cool The solution

    There are two lengths of spud shaft. One for use with the older non-drilled transfer gear, the longer one for use with the newer longer splined drill transfer gear.

    One for the back of mind for those who may consider the replacement of transfer gears in the future.

    Now, find a long splined spud shaft...FTC5090

    Pete
    Last edited by Pierre; 29th May 2013 at 08:40 PM. Reason: part number
    Dizzie, 08 D3 TDV6 SE
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