463 Transfer box issue - 750.653
I’ve noticed recently as I pull away in my 463 (2000) 300DT in high range, the transfer box gear lever moves forward by 20-30mm and back on over run yet In low box the lever does not move at all. I discussed this with another member who thought it may be an indication of ware within the box, as he had the same issue with his 500 which evenly required the transfer box being rebuilt, as it would frequently slip into to neutral under load.
Does this mean when the lever moves forward the gears are not fully meshed so putting additional strain on the gears.
Has any body else experienced the same ?
Hi Howard, I had this on my 500 which had a body lift. The lever never felt as if it engaged and occasionally - in low box - it would 'flick' out of gear: not very pleasant on a steep hill climb. The reason this happened was because the space between the chassis and the gearbox tunnel is very tight and there was a mounting slot (for lack of a better word - like the old Ferarri gearbox stainless steel lever gaits) between the two which channeled the lowbox lever to and fro. In the case of the lifted body, this slot got malaligned on refit and stopped the lever from engaging properly. I only found this out once I removed all central channel cover/ trim plates. It was just a matter of rejigging the mounting slot and I have never had a problem since. I hope this is what you have as it takes about an hour to do and is a lot cheaper than a transfer box rebuild. Regards, Ph
Check the condition of the transfer case mounts and also the gearbox mounts.
Howard,
I'm afraid to inform you that my transfer box lever, once engaged in either low or high, does not move at all. By the way, until I sorted out my issue, I used to ratchet strap my lever in either low of high to stop the thing from slipping out of gear: I realise that this sounds rather drastic, but it did the trick for a whole summer in Greece until I got down to fixing it when I returned to Blighty. I only mention it, because it worked and I was delaying to face a potentially large bill.
Ph
Yes, mine only moves by a millimeter or two. I have not seen this issue on any other transfer box before.
There are some used transfer boxes available on German ebay for around euro-2500. However, I would guess that a good transmission specialist could repair yours with new parts for a lot less money.
Just as an example:
http://www.ashcroft-transmissions.co.uk/
German ebay:
http://www.ebay.de/sch/i.html?_Verteilergetriebe+w463.TRS0&_nkw=Verteilergetriebe+w463&_sacat=0
Possible used one from dublin
Try to contact these people, who are breaking a 300GE near Dublin (contact number in listing):
ebay item:301776327443
Is it basically the same transfer box on a 463 on a 500 or a 300? I know ratios are different but strength of internals? G wagon G has rebuilt his own transfer box, seems nice and quiet now. Not that easy as a job.
The versions are with the high-range either 0.87 (overdrive) or 1.05. The low range is 2.158. I think they are all the same otherwise, but of course some engines now develop over 700 Nm which is a lot to handle.
Later models (2001 >) replace manual shifter with electric motor drive.
Hi
I just recon the power of newer engines hurts the box, plus many have had a tough life and many miles on them
The bearings and gaskets to do the job correctly are costly too. Most recon units are only the parts needed for a short 12 month or 12000 mile warranty
Not good enough really
To rebuild mine with all new bearings etc and no labour cost about 300 pounds in itself without oil or fit and remove
I could of done it for 125 using different bearings but used all the same makes and genuine gaskets etc
The merc one will ,or should have everything done including differential which seemed ok so i left as it was
If i had to do that too it would be a lot more money in parts alone
Hi Howard,
Have you noticed any improvement since fitting the new transfer box? Any smoother?
Try a PM but Howard hasn't been on here recently (>1 year).
Thank you for your post Philias I will investigate the slot. The lever feels as if its engaging correctly, but you can feel it moving forward and back as you move off and slow down.
Gavin, out of interest how much is a new transfer box?