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Transfer-Case Reassembly

Transfer-Case Reassembly

Transfer-Case Reassembly

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

RE: Transfer-Case Reassembly

Ideally, you need to remove all debris larger than the thickness of the operating oil film at the gear tooth and bearing contacts. Don't know any way to do this with your situation though.

RE: Transfer-Case Reassembly

First step: Get a copy of the FACTORY workshop manual/ repair manual/ overhaul manual.
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

my thoughts would be flushing with lots and lots of kerosene or how about and engine shop many times they will have what amounts to an oversize dishwasher

RE: Transfer-Case Reassembly

You can rent a nice parts washer from, e.g., Safety-Kleen, with solvent changes included, for a reasonable amount of money.

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

I really don't know the in's-and-outs of solvent flushing the parts because some of the gears/bearings/clutches/selectors on the shaft would no longer have that needed spec lube to operate properly and the bearing races are pressed-on like no other.

RE: Transfer-Case Reassembly

What does the factory service manual have to say about it?

New lubricant can be obtained and installed. That's not an excuse.

RE: Transfer-Case Reassembly

You can find the information for download that you seek by doing a search for the Land-Rover RAVE manual.


RE: Transfer-Case Reassembly

what do I need with "forum policies" and such? I just asked a simple question and got a half-dozen different answers and none of them helped. I will just stick with my usual forums and sorry to burden you regulars here. Just thought I would take a shot at this one since I was perusing the internet anyway.

RE: Transfer-Case Reassembly

The forums that tell you what you want to hear are elsewhere on the internet.

Sorry to disappoint.

Mike Halloran
Pembroke Pines, FL, USA

RE: Transfer-Case Reassembly

Chubbs878- Here's a couple honest comments in response to your posts above:

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

I believe Chubbs is reading the signature on Greg Locock's post, thinking it is directed at him.

RE: Transfer-Case Reassembly

I believe Chubbs is no longer reading anything at Eng-Tips.com

je suis charlie

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