Transfer box operating rod problem

Mar 02, 2007 3 Replies

I've lost the ability to change between low/high transfer gears or select the diff-lock on a 1998 300Tdi 110. The transfer box is in neutral at the moment.



The cause of the problem is that the part that links the threaded end of the operating rod and the clevis pin attached to the high/low lever on the box itself has sheared (looks like a fatigue fracture) where it joins the rod, leaving part of itself attached to the rod and the rest to the high/low lever clevis pin.



The workshop manual says that before removing the transfer box you must "Remove retaining clip and disconnect high/low lever from operating rod". This seems to imply that the joint can be disconnected (and refitted) by removing the clevis pin without dropping out the transfer box. The problem I'm having is the pin has it's head towards the transfer box casing and there doesn't seem enough room to withdraw the pin before it hits the casing which prevents it's removal.



Is it possible to get this pin out (and refitted) or do I need to (groan) drop out the transfer box?


Why don't you cut the head off the pin with a suitable hacksaw (junior or otherwise) and pull out the other way and then replace with new pin.

Martin

In message , Oily writes

That thought has occurred to me - I just suspect that the design intention puts the pin the way round it is to prevent it easily falling out if the clip comes off (not that I can imagine the clips accidentally coming off - there's no real water-spray or mud issues that high up the vehicle) so it may be better to keep it the same way round.

"Tim Willets" wrote .....

Can't you just slacken the 10mm headed bolt on the top clamp and slide it sideways to give you the space to get the pin out? I should have suggested that before, got to get the brain in gear. :-)

Martin

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