I needed to change the chain because of the well known issues. See this post for the details:
http://rangerovers.net/forum/viewtopic. ... sc&start=0
Gathered all the parts, studied rave for several days. I paid a garage to take out the transfer case for me. My wife and I took a half day on Friday and got to work. Yes I said my wife, she proved to be very handy, didn't even mind getting all dirty. Here is what we did:
This is the case before I started
You will need a 30MM socket to get the bolts off the drive. I replaced 4 seals in total, 2 on each side of the axle. The big one was about $25 from the dealer, the small one was $4. Here is the part for the larger one (don't have the part number handy for the smaller one):
Here is the drive shaft flange off with the nut. I used a air impact gun to take the case apart
Flange off the axle:
Here is the other side of the unit with the flange and cover already off:
We then carefully pryed the front and back half apart, this part took some time.
When it was apart you could see the cause of the problem, a very streched chain. Everything else looked very good, NO METAL. gears and bearings were perfect. Good thing too because each bearing unit is over $125 from the dealer.
Here is the other half of the unit.
At this point we took the unit apart to get the new chain on there. This proved to be the most difficult part of the project. It took awhile before we found the correct angle to get the chain on there. You can see, the new chain is much more snug then the old one:
At this point we cleaned all the old gasket material off all parts with a razor blade, brake cleaner and elbow grease.
We are going to let everything dry overnight. Tomorrow we will put the new RTV gasket on and seal it up. We will then wait until Monday to bring it back to the garage for install back on the truck.
The job took about 4 hours, start to finish. We went very slow and took lots of pictures.
http://rangerovers.net/forum/viewtopic. ... sc&start=0
Gathered all the parts, studied rave for several days. I paid a garage to take out the transfer case for me. My wife and I took a half day on Friday and got to work. Yes I said my wife, she proved to be very handy, didn't even mind getting all dirty. Here is what we did:
This is the case before I started
You will need a 30MM socket to get the bolts off the drive. I replaced 4 seals in total, 2 on each side of the axle. The big one was about $25 from the dealer, the small one was $4. Here is the part for the larger one (don't have the part number handy for the smaller one):
Here is the drive shaft flange off with the nut. I used a air impact gun to take the case apart
Flange off the axle:
Here is the other side of the unit with the flange and cover already off:
We then carefully pryed the front and back half apart, this part took some time.
When it was apart you could see the cause of the problem, a very streched chain. Everything else looked very good, NO METAL. gears and bearings were perfect. Good thing too because each bearing unit is over $125 from the dealer.
Here is the other half of the unit.
At this point we took the unit apart to get the new chain on there. This proved to be the most difficult part of the project. It took awhile before we found the correct angle to get the chain on there. You can see, the new chain is much more snug then the old one:
At this point we cleaned all the old gasket material off all parts with a razor blade, brake cleaner and elbow grease.
We are going to let everything dry overnight. Tomorrow we will put the new RTV gasket on and seal it up. We will then wait until Monday to bring it back to the garage for install back on the truck.
The job took about 4 hours, start to finish. We went very slow and took lots of pictures.