Transfer case components
1 – transfer case; 2 – top bracket; 3 – sealing ring; 4 – sealing ring of the front right axle shaft; 5 – intermediate rear bearing; 6; 7 – Round sealing ring; 8 – rear drive output sealing ring; 9 – closing plate; 10 – Drive rear connector; 11 – oil level indicator
The transfer case is located in the front drive shaft axis, behind the engine. It distributes and controls the drive torque to the rear wheels via a planetary interaxle differential. This design solution divides the torque in the following proportion: 53% to the front wheels and 47% to the rear. The front drive axle with a classic differential divides the torque between the two front wheels. The electromagnetic locking ensures a rigid connection of the intermediate planetary gear.
Box type: TK2A.
Removal the transfer case
Fig. B: V – drain plug, 1 – rear engine bracket
Figure A: 2 – Travel limiter flange
Information posted on the website www.PeugeotBook.ru
The transfer case is removed from underneath the vehicle.
Removal
1. Drain the oil from the transfer case and the fluid from the cooling system.
2. Remove the drive shafts.
3. Remove the upper fastening element of the transfer case oil level indicator guide. Remove the oil level indicator guide from the transfer case.
4. Unscrew the stabilizer bearing mounting bolts and the steering gear housing mounting bolts to the front crossmember.
5. Remove the lower engine bracket connection clamp.
6. Unscrew the bolts securing the center differential lock motor.
7. Remove the travel limiter axle.
8. Unscrew the engine crossmember mounting bolts, having first installed a telescopic support underneath.
9. Remove the crossbar (this must be done together).
10. Remove the travel limiter and its clamp.
11. Install the steel rod so as to prevent the front part of the drive shaft from falling out, and then unscrew the bolts that secure the front flange to the drive output connector.
12. Remove the drive shaft (do not separate the front part of the shaft from the intermediate bearing, as this will cause loss of balance).
13. Neutralize the action of the automatic locking cable tensioner by turning it a quarter turn.
14. Remove the differential lock motor control cable.
15. Remove the gearbox control.
16. Remove the water inlet housing into the cylinder block.
17. Disconnect the speedometer drive cable from the transfer case.
18. Install a telescopic stand under the transfer case (put a wooden block underneath).
19. Remove the upper transfer case mounting element.
20. Disconnect the differential lock indicator light connector.
21. Remove the right transfer case bracket and unscrew the bolts securing it to the gearbox.
22. Remove the transfer case from the right side.
Installation
1. Installation is the reverse of removal. Be sure to install the transfer case with new sealing rings, lubricate the left drive shaft bearing area with Molykote BR2 Plus, install new self-locking nuts, lubricate the rear drive shaft bolts with Loctite, and tighten all bolted connections to the appropriate torque.
2. Fill the oil, coolant and bleed the cooling system following the recommendations for using operating fluids (see subsection 2.1).
Transfer case repair
Only seals and O-rings need to be replaced, as they are the only ones available as spare parts.