200tdi transfer box replacement

Hi, could anyone please tell me how difficult it is to replace my transfer box or put up a link to guide? I've done a search and can't find anything for a 200, how difficult is it? and can it be done without removing the main box?

Many thanks in advance.

Yes can be done without removing the main box, but you will have to support the main box somehow as all the mounts are on the transfer box.

Start by removing the prop shafts and disconnecting the diff lock light wire and the hi/lo/diff lock lever.

Drain the transfer box of oil.

Remove the 8 (?) bolted round cover on the rear of the transfer box and remove the gear off the shaft. The transfer box is attached to the main box by a line of bolts right round the joint between the two.

There is very little room above and behind the gearbox because of the shape of the floor and you will have to lower the rear of the main box slightly to get the transfer box on and off.......there is a shaft that comes out of the main box. Also watch out for the oil seal in the transfer box that can get damage in removal or refit.

As above, yes I agree but I would also remove the engine fan thus allowing you to drop the rear of the gearbox a little to give more flexibility. I did this job recently, its not too bad at all, one tip i got from this forum, fit a piece of all thread into one of the bolt holes, about a foot long, this will stabilize the box so you can safely put your trolley jack under the heavy bit, also for putting it back, the all thread makes the job much easier.

I did mine on my own, on my drive with no lifting gear bar two trolley jacks. Transfer box first and then the main gearbox, Also refitted them as two items too.

Good luck...

Thanks a lot mate, you make it sound quite easy, just had a look at guide for a 300 and it looks a little beyond my skills, just have to get my friendly mechanic to do it when he's got time.

bit more, there are two bolts from the front side too and also remove the gearbox output gear first, bit fiddly but possible.