Transfer-Case Reassembly
Transfer-Case Reassembly
(OP)
I am swapping the front output housing on the TC of my 2003 LR Discovery. As part of the process, I may need to also exchange the differential/intermediate shaft. It has been exposed to the elements just a tiny bit and I would like to know how to clean all of these parts to spec. I do not intent to disassemble the bearings and gears as they are pressed on in a fashion that dissassembling will cause damage to at least the output bearings resulting in replacement and so forth; plus I don't have the tools for that process. Anyway, I need to clean everything as it stands, and lubricate everything properly before I install it onto my existing box. Please advise in all steps required, along with specifics such as type, make, brand etc. I was thinking a commercial parts washer but taking that route would require complete disassembly in order to apply assembly lube, would it not? I have never done this before. Much thanks.
I have several photos but only able to upload one per post
I have several photos but only able to upload one per post





RE: Transfer-Case Reassembly
RE: Transfer-Case Reassembly
Cheers
Greg Locock
New here? Try reading these, they might help FAQ731-376: Eng-Tips.com Forum Policies http://eng-tips.com/market.cfm?
RE: Transfer-Case Reassembly
RE: Transfer-Case Reassembly
RE: Transfer-Case Reassembly
RE: Transfer-Case Reassembly
RE: Transfer-Case Reassembly
RE: Transfer-Case Reassembly
They can be pricey, but are generally much better than the aftermarket manuals.
( For American and some imported brands, the source is helminc.com.
They do not seem to cover Land Rovers. )
Study it cover to cover.
When you have read every page at least six times, you are ready to start disassembly.
Mike Halloran
Pembroke Pines, FL, USA
RE: Transfer-Case Reassembly
RE: Transfer-Case Reassembly
I suggest you do; there appears to be some nasty particulate in some of your photos.
The dangerous contaminants are the ones you can't see, because you didn't disassemble enough, or flush enough, or blow out enough, or wipe enough, or scrub enough.
If you don't get it all out now, you get to do it all over again, _and_ replace some parts.
Mike Halloran
Pembroke Pines, FL, USA
RE: Transfer-Case Reassembly
RE: Transfer-Case Reassembly
New lubricant can be obtained and installed. That's not an excuse.
RE: Transfer-Case Reassembly
Cheers
Greg Locock
New here? Try reading these, they might help FAQ731-376: Eng-Tips.com Forum Policies http://eng-tips.com/market.cfm?
RE: Transfer-Case Reassembly
PJGD
RE: Transfer-Case Reassembly
RE: Transfer-Case Reassembly
Sorry to disappoint.
Mike Halloran
Pembroke Pines, FL, USA
RE: Transfer-Case Reassembly
First, the only practical method you have to clean your components without complete disassembly is flushing/brushing with new part washing solvent. Make sure the parts washer pump has a filter to keep from recycling debris in the solvent back into your components. As shown in one of the photos posted above there will be many areas where sludge has accumulated. It is important to remove this sludge since it contains abrasive material. It will help to soak the components in the parts washing solvent overnight to loosen the sludge before flushing. After flushing, allow the components to drain and then use dry compressed air to remove any trapped solvent. The components should be allowed to air dry so that no cleaning solvent remains. You must remember that without complete disassembly there is no way to be sure all debris has been removed.
Second, in one of the photos posted there appears to be a fair amount of corrosion (rust) on some helical gear tooth surfaces. Corrosion on steel gear or bearing surfaces subject to hertzian contact is a problem. Even if the visible corrosion layer is removed, there can still be small pits that will initiate fractures and surface spalling. If you expect to get decent service life from this overhaul I would recommend finding another gear set that has no corrosion present.
Third, since you are rebuilding the TC with used parts I would not think any special assembly lube is needed. The parts have already been run-in. A generous coat of the specified lube oil just prior to assembly should work just fine. However, you need to be careful about mixing used gears or bearing parts from different assemblies. It is usually best to use a set of mating parts that have been run together when overhauling with used components.
Lastly, you should replace all elastomer seals after solvent cleaning, since they may likely be degraded.
Good luck with your project.
RE: Transfer-Case Reassembly
RE: Transfer-Case Reassembly
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