Angle drive flange removal

[conor]

On the 020 syncro gearbox, The front end of the propshaft connects to a 3 pronged flange, with a rubber donut in the middle. My question is, can the 3 pronged flange on the gearbox be removed? One of the studs that bolts the propshaft to the flange has sheared off. I inspected it and it looks as though a large nut holds on the flange, has anyone removed one? I’d like to do it without removing the box if possible.

[LD50]

I’ve not removed that myself but here’s a couple of pages from etka which may be of some use?

EDIT: Actually I just remembered I have an 020 transfer box in bits in the shed, lemme have a quick look and see if there’s any clues as to how it goes together there…

• This reply was modified 7 years ago by LD50.

Attachments:

1. syncro_drivetrain_1.pdf
2. syncro_drivetrain_2.pdf

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[LD50]

ok so I just had a look at the disassembled transfer box and whilst you can remove the 3-pronged bit, it does look like the collar of that helps centre the shaft which exits the transfer box, so it may not be a good idea to do so.

That said it may be possible to duplicate the locating collar minus the 3-pronged flange with a bit of steel tubing appropriately turned on a lathe, which when bolted on might mean you could safely continue driving minus the 4wd. I might be able to help with that if needed as I have a small lathe as well as all the parts to take measurements and make a duplicate part.

Obviously I wouldn’t be able to recreate the splined section but if you’re not providing drive to the rear then that wouldn’t really matter. The replacement section also wouldn’t be the same type of steel (different hardness, mild vs engineering steel) so should probably be considered a somewhat temporary solution.

What I don’t have is the nut & any washers which might secure the 3-pronged flange so there may be a bit of guesswork there. The bits I have are the leftovers from a transfer box which was cannibalised by a garage which worked on my syncro a long time ago so it’s sorta “misc transfer box bits” :-\

• This reply was modified 7 years ago by LD50.
• This reply was modified 7 years ago by LD50.

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[Chris S]

I have a complete transfer box here if you need it?

[LD50]

that would of course work even better 😀

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[conor]

Thanks so much for the info and the photos, really helpful. It seems like it is a bt involved to dismantle in situ, I’ll just have to remove the whole lot to fix it.

Thanks for the offer of a transfer box but I am going to try and drill out the broken bolt first, and go from there

[LD50]

no worries, glad it was helpful 🙂

tbh doing anything in that area in situ is gonna be a royal pain in the ass, including getting the whole transfer box off to replace it. Keep us posted!

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