LT77 Transfer Box Flange Renewal

Hi all ... noticed a metallic grating sound coming from the transfer box on my new 200tdi 110. I thought time to drain and refill with EP90 so I undid the drain plug and out plopped a small amount of black tar and a little water! ... Filled up with EP90, took for a drive and when I got back noticed the EP90 was pouring out of the front flange area. Also a fair bit of play in the front prop so I've bought a new flange, seals and bearing and wondered if it's a straight forward job? Anyone done this before that can lend a pointer or two?

I've changed the bearings on the input shaft on the old LT77 so I'm going to do that at the same time but never had to change flange, bearing and seal before.

Friendly words of advice welcome ... please and thank you

All straight forward enough, no hidden nasties. Just make sure you press the seal in square, other than that it'd be hard to go wrong really

remove flange ,seal and circlip refit flange loose andpry shaft and bearing (stc1130)out ,grease garter spring in seal when you refit it

Thanks guys ... sounds like a job I can do easy enough then ... will order some Timkens for the input gear while I'm at it.

Does the flange come out as easily as a diff flange, or do you need a 3-leg puller as Haynes suggests?

busters got a how to on this somwhere

oh, and a tip if you aint got any fancy locking tool.
I used a breaker bar on the nut, put it in low box, in gear, decided if it was 1st or reveres I needed (cant remember now) wedged the bar againt the appropriate side of the chassis.

Start engine, foot on the brake, let clutch out gently, you might need to do it a couple of times, but it undid mine nicely

timtheenchanteruk said:

HERE you go!!!

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Thanks for that. So it looks like the Flange just pops off the shaft, and doesn't need any sort of puller. That's good news.

Dobbs said:

Thanks for that. So it looks like the Flange just pops off the shaft, and doesn't need any sort of puller. That's good news.

Click to expand...

some times they need some help ,copper hammer is best but ordinary one will do if your careful