Snapped transfer box lever
(N)ever seen or heard anyone doing this before?
VG080 Xfer box lever from my W460, snapped clean off! fortunately there is a new VG150 on its way :-)
i had that hapen to me on holiday in france once got the campsite oddjob man to weld
it back together 6years ago still the same today
in about 1991 messin about offroad a fat guy hit his head on the roof
and landed on it (broke his cockolox) little bone in your bum
and bent it after 2 bottle of wine on holiday YEARS LATER i will bend that straight
it came off in my hand OOOPS
I am no metallurgist but looking at a poor definition photo for my eyes, it looks like porous material, notice the shine in the center which shows a fresh break. The dull material either side of the 'shine' is old shear; discoloured.
Closer inspection today and it seems like a much more serious failure of the transfer box alongside this cosmetic one!
The remaining part of lever has become disconnected and floats loose within the box. Unable to select anything and making a quite unpleasant noise. Time for it to go I think!
Video below.
https://www.flickr.com/gp/benstoneham/eQEdW4
Looking at the transfer box parts illustration below, it seems that possible the gate or guide (92) may have failed given the sloppiness of the lever as you have posted. It could be repairing of parts above of and possibly lever 107 needs to be looked at and not necessarily the whole transfer box. So the job could entail in removal of transfer box and a lever top strip and repair at best.
Thanks Rakesh - I'm actually about to switch the axles and box for a set of 463s anyway. Once its out though I might well do as you suggest and pull it apart to rebuild. It will be interesting to see what the problem was.
Glad to see you are changing the axles and transfer box as a set for the the propshafts travel in different directions from transfer box to front and rear axle on the W460.
Where as, for the W463, the front and rear propshafts travel in the same rotational direction from transfer box to front and rear axles. This means the crown wheel and pinion of one axle is in reverse order otherwise, one axle travels in a forward direction and the other turning in reverse at the same time.
This would imply you are also going to transplant the locking diffs arrangement as the W463 employs a hydro-pnematic arrangement to engage diff locks.
Yes that would be a classic mistake! "errr.. its not moving... I know, I'll just give it some welly!"
Transplant has been planned for some time because the VG080 would not have taken the torque I will be putting through it wit the new engine and gearbox (around 1600Nm max in theory). The VG150 is rated at 1500Nm whereas the VG080 just 800.
As far as diffs are concerned, I'll just fabricate something to adapt the hydraulic engagement from the 460. For what this truck is going to be doing (Rally Raid), diff locks aren't going to be used that frequently (I hope!)
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its obviously not as unusual as I thought then.. very strange place to break, but I suppose that with vibration over time.. I could probably weld it but I think I'll take it apart and fabricate a replacement when I have a mo.