Hi guys & dolls.

I would like to know how the transfer box comes out on my 03 Octavia 4x4. The reason for this rather extreme request is simple if not long winded!

The car has suffered for some time from an exhaust blow from the manifold area, I've been putting it off but now have the use of a company car. This has prompted me to get it stripped & investigate. I removed the 'gubbins' to expose the exhaust manifold & could clearly see a crack between cylender 2 & 3, Great, all i have to do is get the manifold welded, easy! While removing the 3 bolts that hold the turbo to the manifold 1 snapped! I removed the maifold & found a couple more cracks. ****! Now all i have to do remove the turbo. Everything was going great untill i found that the bolt on the bottom bracket to the turbo is way too tight. My numerous attempts have failed. This bracket is bolted to the engine block BEHIND the transfer box! So, O/S drive shaft off, Prop unbolted & the 4 bolts that hold the transfer box to the gearbox off. The transfer box rotates & comes away from the gearbox about 2 or 3 mm but despite my best efforts i cannot get it out.

So here i am. Does anyone have any suggestions? After 6 hours in the garage i am stumped!

Off for a soak in the bath to calm down :eek:

Thanks in advance.

Dave.

Have you unbolted the output flange from the diff for the o/s driveshaft?

No.

I had a quick feel around but didn't find any kind of fastener in the bottom of the output flange.(it was full of grease tho!)

I will have another rummage tomorrow.

Thanks for the input & i will keep you posted.

Dave.

There is an allen key bolt (6mm iirc) down the centre of the flange, this bolts into the diff so your not getting the tx box off without bolting thet first (not without damaging the diff anyhow). Allen key is about 6-8 ins long though to get down there.

As for the sticky turbo bolt, it's probably heat/rust welded into place. Before continuing with the xfer box, try giving it a good shot of PlusGas (or similar)(Not Water Dispersant-40; clue is in the name), and leaving for 15 minutes.

Ken,

We are well past the penetrating oil stage for the bolt. It has rounded off with my numerous attempts, hence the requirement for removal of the transfer box!

Just got in from work & about to venture into the garage.........I shall report back later

Once again, thanks for all your input!

Dave.

Update.

After manufacturing a suitable 'tool' to remove the 6mm allen bolt from the o/s driveshaft flange, the transfer box is out & the troublesome turbo bottom bracket un-bolted from the block.

With the turbo in the vice & a 'little' persuasion the offending bolt is removed!

This will be substituted for an allen key bolt for ease of assembly

Now all i need to do is remove the broken bolt from the turbo & get the manifold repaired, how hard can that be!

Can i take this opportunity to thank Lummox & KenONeill for their assistance in my moment of need, you are both stars :thumbup:

Dave.

Your most welcome.

Sorry to revive a very old (4 year old) thread here but I did search and can't seem to come up with any solution or topic covering this. If there is one please forgive and direct me to it. I have the transfer box completely free from the gearbox but cannot drop it out as there is a mounting/bracing bracket on the o/s which is completely undone but is stopping the case coming off and the case is stopping the bracket coming off.

The only solution I can come up with is to cut the bracket in half and remove in two sections but this is obviously not the correct or Desired solution.

How did everyone else remove the bracket and transfer box after the four main bolts and the one inside the o/s flange so the transfer box is loose and coming away.

I have the car stuck up a ramp and desperately need it finished. I have the new transfer box to replace.

I could also use knowing what grade of oil needs to be put into the box.

Cheers in advance

Ended up using welding torch and cutting the brace into 3 sections to remove and still be able to brace the replacement part back up.