transfer box

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g wagon g
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On Saturday, after fitting gearbox i really could not be bothered but while it was on pit i thought i had no option

Why i doubted myself i dont know but i had to be sure

Removed outer covers and plate and speedo gear drive

Got new digital depth gauge and checked bearings about 20 times each for shims

Made a qiuck tool to load bearing outer races

They were spot on

Now the bad bit

I decided that there was no option but to remove rear prop and check diff bearings

I was sick of doing prop bolts and fine threaded nuts

Prop off and all bolts off cover. No where to put a pry bar but got the bottom edge just free

Could not get to top to lever off carefully and evenly

Few fine chosen words later

I have a low miles transfer box sitting in garage

Do i just fit that one or dont i

Glutten for punishment i removed transfer box

I was starting to remove parts off spare transfer box that were still attached

Gave flanges a check for play. There was slight play on front shaft flange, very slight

I thought i would refit mine and strip spare at leisure

Got diff casing off while on floor and checked that about 20 times too. Its old age

Cleaning sealer off with a stanley knife blade and it all went bad from here. It was about 9 pm

I needed a beer but thought no just get it finished and put it in tomo morning

Last bit of sealer and ready to thinners casing grease free for re fit

Dropped stanley knife blade in transfer box !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

Tinkle tinkel off every gear to god knows where in box

Space is so small i gave up. Cursed myself 100s of times and decided a beer and a cigarette, or 20 beers

To have to remove end cover for that was almost anger management classes

Kept calm

The gap is so small between gears and casing and you cant see in as its so tight. Looking at it i was amazed it fell in. Insult to injury i had covered it up with a cloth to stop bits going in

I had left oil in and thought tip it up and hope for best. Got brain tub and tipped it up

I was tired but how heavy can such a small thing be. I was holding it over oil drain pan thinking hurry up and drain

Placed gearbox on floor again and got a pen light. Could see nothing and then when oil settled i saw the bevelled edge of blade

This sukkker aint getting through here

I got a tig welding rod and my dial gauge magnet and tested it. Picked up nothing so gave up on that

Magnetic screwdriver with welding rod in

That was shite too

The only chance i had was to pick blade out on edge and it just might clear. Just being a proper one shot just

I had a brainwave

​Smash casing off and glue together with liquid metal. It says its stronger than steel. 

Only kidding, its not and i would not do it

A brainwave. The gap is about 5mm if that between diff and casing. Eureka i found a magnetic tape measure with 2 strong magnets on the end. Its my favorite tape but its better than a full strip down if it works

Cut a magnet out of tape measure and stuck it on end of welding rod. Another beer to calm my nerves if it went wrong

Pushed small magnet past and it picked blade up so easy on its end. Bugger me it came out first time

TOP RESULT

Its now very late and early hours of morning . I thought just get box back in as i am dirty and tired

Put in and then decided to finish the job so i did it all and the last thing i wanted was to be getting gear oil the smelly stuff on me Sunday so hell yes i did it all and it was finished

So basically i doubted myself. Did all that for nothing

Took g for a long run on sunday and noise has gone. 2 Gear boxes making the same noise. Doubtful but its silent now and good as gold

                           Happy Days

My G wagon is the only thing i like to work on and love to bits. I have had many many cars and projects but i just love it so much i dont mind the work to make it better

Cant be anything else left to do

Had a look at rear wiper washer and it was the motor and the sunroof im not sure but i can live with that for now

                           Happy G wagoning folks

g wagon g
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Re: transfer box

Come on guys

Some of you are well more educated on g wagons than me. I just modify them

Post up some stuff

How about sunroof as im baffled without a full strip down. I said there must be micro switches but i am told there is none

How does the sunroof know its closed , open or tilt???????????????????????

Please help so i dont have to strip down all of it to find a simple switch etc

I would appreciate some help here guys and i will help you as much as i can on other subjects

Someone must have done a 6 speed box and done transfer box so give us all some input for good or bad

Hey its for all and mine might be good but other opinions would help to contribute to a perfect combination

Give us all some info please

Arnie
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Re: transfer box

g wagon g wrote:

 

How does the sunroof know its closed , open or tilt???????????????????????

Please help so i dont have to strip down all of it to find a simple switch etc

 

 

As far as I know there are no micro-switches on the sunroof parts themselves. However there are supposed to be some micro-switches in the motor-drive unit, that may require adjustment from time to time. The system is the same as that from the W124, W140 etc and there is some detailed service information on the web and other MB forums - just google it.

eg: http://www.benzworld.org/forums/w126-s-se-sec-sel-sd/1458882-sunroof-layout-repair-pdf.html

The motor mechanism is behind the rear left quarter-panel trim. remove rear-door edging and slide out panel

Your transfer case post was entertaining. I have a policy of not doing any such work at night as there is a saying that you see the results in the morning. However, you managed to get out of a sticky situation.

 

g wagon g
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Joined: 21.04.2014
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Re: transfer box

Cheers Arnie

Yes it was a sticky situation that was just shit luck to be honest

The good lord was looking over the g wagon that night

He could of told me it was fine before i took it out lol