86 323 BFMR Turbo 4WD Transfer Box Issues

[Rentakill]

Hi Guys


First time post for me.
Have got a 1986 323 4WD DOHC Turbo that has just started making a Rotating dry metallic noise when driving.
Investigating the undercariage of the 323, i have removed the Drive Shaft from the Transfer Case and checked the Hanger Bearing halfway down (Actually Replaced the Bearing for the hell of it).
Then Test Run, still to find Noise when driving.

After getting it back in my Garage, i then jacked the Car up off its front wheels, and dissconected the drive shaft from the Transfer Case coupling again.
This time, i ran the 323 up in gear to see if the noise was Gearbox related.
On running up, the noise is plainly obvious that it is coming from the Transfer case that is bolted to the Gearbox.

On closer look it seems that the Seal behind the Driveshaft coupling has failed and drained the box of its lubrication, causing possibly at best a Bearing to Run out dry.

What i have done is started to unbolt the transfer box, so i can then inspect the bearings internal to it.

What i would like to know, Is, Can the Transfer Case be removed while the Gearbox is still in Situ ?
I have unbolted all the Bolts which hold the transfer Case onto the Gearbox, but find that the Transfer case doesnt want to be pulled out..
It maybe that the bearing housing has become Heatdamaged and litrally heat Glued itself in its housing, or alternatively the Gear arrangement/Meshing maybe whats holding it back.

Can anyone thats done this job before, give me some advice ?
I was hoping to avoid removing the complete Gearbox..

Its seems also that the Gearbox and Transfer box are both separate when it comes to Lubrication, as checking my Gearbox oil level showed to be fine.
The Transfer case was however dry..

I look forward to any feedback..


Cheers

[therieldeal]

the rear transfer case is one combined casting with part of the gearbox. you are going to have to drop the whole thing.

[nerd racing]

I have disassembled a BG GTX box and the center differential had to be removed in order to remove the transfer case. I am pretty sure the same will be true for the BFMR.


Jay should know for sure, at least for the BG box.

[trailrider098]

yes, there is a seal between the transfer and main so fluids are sepperate.

i thought that the transfer came right out but it does not, will require complete transmission disasembly

blurry pics of BFMR FSM

in the 37 steps of disasembly remove the transfer is #36

[Rentakill]

Hi Guys.

Thanks for the Quik Replies.
Hmmm.. Bugga. I was hoping that the Transfer Case that ive unbolted would just drop off,, As all it looks similar to a Diff Head. (See Pic)

If i have to drop the whole box, just to get access to the Output shaft seal, what a frikkin mission its going to be.

What i need confirmation is, who's been there done that.
I have a full copy of the Manual here myself, The part that covers the Transfer box removal is very vague and leaves it very open to interpretation.

A word from the Horses mouth is all i need.

If the box has to come out, it comes out.


Once again, Cheers:

[trailrider098]

to do the rear seal try blasting off then nut on the output shaft and pry the seal t with a hook then instal new seal. im not sure if it works like that but it might and it would be easy

[808]

I love that paint scheme so much... I'm so jealous.

[nerd racing]

if I remember correctly from my dis-assembly (for shipping weight purposes) you should be able to get to the seal by taking that flange off. you may have to use a pulley puller to get the flange off if its a tight fit.

[Rentakill]

Yeah.. She has a good paint Job.
Pretty original.
For having 350,000 on the clock and never having touched a thing except One Clutch, shes done more than well.

You comment about removing the seal while in situ is possible, but as well as needing to replace the seal, i also need to get inside the Transfer case to find the bearing that ive run out..
Now that ive got to pull the whole box, i might aswell give the whole box a looking over.

Ive started dissassembling the Gearbox from the Motor.
So far 1 hour and getting there.
Doesnt look to bad.
Have removed the Battery, Air Filter, disconnected Gear Cables, Electrics, pulled CVs and Drive shafts.
Not far from unbolting from Motor block, releasing Mounts and dropping out.

I managed to dissconnect the Speedo Drive gear earlier on, hoping that this would allow separate release of the Transfer box.. Saddly not.

Will keep ya posted.

Cheers

[nerd racing]

good luck man, those boxes are heavy! The trans in my car now weights about 50 lbs wet compared to over 150 lbs! (I have an E-series fwd trans at the moment)

[happygtr]

transfer carrier comes rigth off. somtimes loosen rear mounts to get cleareanse.

been there wrecked that 11 boxes

[Rentakill]

Gidday HappyGTR.

So are you saying that you have worked on a 4WD Transfer Box while the Gearbox is still installed in the Car, and successfully removed the Transfer box ?
Did you have to remove the Speedo Gear Drive before the Transfer case was able to be pulled from the Gearbox ?

[anduril]

the T-case can be removed while the box is in place....there is a aluminium plate with an exen tric shape with like 12 bolt on it on the side of the box.... remove only the exterior bolts.... take a pry bar, and pull that thing until it stop (about 1 inch...) after, you unbolt all the bolt on the T-case... after that, pull the transfer case....

hope that is clear... if it's not, put a picture of the driver side of the box....

[anduril]

the cover that i'm talking about is the #5... on this picture....

[Rentakill]

Hi Anduril

Thanks for your Reply.
Yes.. I know what you mean.
After removing the complete box, i saw that Octagonal Plate you speak off.
Ive since just sent off the complete Trans to a Transmission specialist to get the once over.
Shes done 350,000 Km so far, so deserves a birthday.

While i have the Transmission out , ive done over the Starter Motor, Alternator and all Rubber Hoses that conduct Fluids for the Engine Cooling system.
All Belts, Cambelts and Water Pump have also been changed.

Id probably best call it a "323 Shut".

The next no doubt will be the motor..

BTW - I have the complete 323 BFMR service manual in PDF if anyone wants it.
Its around 60mb , 800 pages.. So could organise to upload it to Megaupload, rapidshare if needed..


Cheers