Transfer Box – More Rebuilding

I recieved the new transfer box parts from Dunsfold Land Rover this afternoon.  This enabled me to fit the transfer box output shaft to the casing and fit the bearings.  I fitted a new thrust washer and circlip on the forward end of the shaft to replace the slightly worn washer and broken circlip (only 60% of it was present, and there was no trace of the rest in the bottom of the  box or in the oil).  This has put the high range gear end float back to just over 0.15mm, which is perfect.  The circlip was a swine, and needed Helena’s help.  I have loosely fitted the speedo housing so that I can set the bearing pre-load (the housing pushes forward on the output shafts rear taper bearing, increasing the preload the closer the housing gets to the transfer case), but I don’t expect to need to change the number of shims as the bearings show almost no signs of wear.

I also fitted the new transfer selector shaft with the new block and special bolt, after soaking them in white spirit to remove the preserving wax.  The shafts can now be re-assembled and fitted to the 4wd housing, and that in turn fitted to the transfer box.  That’ll be done on my next day off – I ran out of time today, having finished working on the engine and also repairing my lawn mower before cutting the 8″ long grass!