Rally Transfer Box Removal

[mk21147]

My transfer box is leaking oil & I need to remove it to have it rebuilt.

Has anyone removed there transfer box with the engine in the car, & any advice on how to do this.

I am hoping it’s just a matter of dropping the front sub-frame down.

Thanks Richard

[Audi Doody]

Hi Richard, I have never had any success with removing the transfer box from below on my rallye, i’m not even sure it can be done.

I’ve tried 3 times, gave up each time and ended up removing the front of the car and dropping the entire engine/gearbox on the subframe.

Sounds a lot of work but I have changed a gearbox this way and completed it in a day.

Tip….if you do it this way, label all the wiring so you know where it goes, makes life so much easier for reassembly.

Hope this is of some help

good luck Mike

[ld50]

I have no idea how anyone manages to do transfer box etc from underneath, even on the gti it’s easier to take the motor out to fiddle with clutch + box. Plus then you can see all sides of the engine and have room to work.

I find it’s an afternoon to take the motor out and another to shove it back in.and generally less grazed knuckles and paintwork.

hope that helps a bit.

Hope that helps.

[vr6will]

definately enging out job. Having just done this, i cant imagine how i’d even start thinking about removing the transfer box with the engine still in.

[mk21147]

Thanks for the help. Thats not what I wanted to here as this will have to be done outside the house. Also I do not know how long it will take to have the transfer box rebuilt. Some one mush have done this?? Please help.

Richard

[mk21147]

Had a reply on Ed38 forum, what do you think?

you;’llhave to remove the offside drive shaft and drive flange (hint, if it won’t knock out there’s a bolt down the middle of it) and the 3 bolts that hgold it to the prop. you might find it easy to drop the prop bearing support too so you can swing the prop out of the way.

then it’s just a case of removeing the brace to the engine, and the bols holding the transfer box to the gearbox.

drop the oil from it first….

[Audi Doody]

Ok for a start where is the oil coming from? Get under the car and check the offending output for up and down play. if it seems ok then get the oil seal for it. swap it over and see..might be worth it.
As to the best way, the thing is, for everyone you ask you will get a different answer…so which one do you choose?

If I was in your position, I’d try the seal thing first but if either of the bearings are worn then the rest of the transfer box is most likely in the same condition.. so get another one. I would take the engine out of the car and most likely replace the clutch at the same time (VR6) clean the engine bay, paint the engine, waxoil the chassis etc.

You pays yer money and takes yer choice.

[ld50]

tbh I think the overriding thing here is that this is potentially a bigger job than it looks and may not be something you’d want to attempt in the street with either method. Whereabouts are you based?

Sounds like you could do with a competent syncro-friendly garage….

[mk21147]

I am based in Leeds. Think I will see if I can do it at a friends House.

[ld50]

mate’s house is a good idea…

simply being able to leave it overnight in relative safety would probably make it a lot less of a headache.

[no such user]

Still no answer as to where the oil is coming from. If it’s the output flange at the back then if you can get the car up high enough it’s possible to do it in situ – I know, I’ve done it recently.

[mk21147]

The oil seems to be comming from where the transfer box bolts to the gearbox, very hard to tell.

[blue95]

I have recently changed the t/box on my corrado (with rallye g/box), without removing the engine or g/box.

You will have to remove the prop, drive shaft, downpipe (possibly manifold as well). But it is possible.

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