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Transfer box failure? - No! Melted Overdrive!

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Singlefin:
Morning chaps, hope the festive excesses haven't killed off too many brain cells; I need to pick your brains!

I think my transfer box has given up the ghost - it started making a terrible clattering and smoke poured out of it. When I put the transfer box into neutral and the main box in gear there was no noise so I'm fairly sure it is the transfer box - are there any other checks I could do?

Is it possible to remove the transfer box in a S3 without taking out the whole gearbox?

Thanks in advance!

Happy New year!

Lucy1978:
sounds like you've been running it with no oil.

I s'pose in theory you might be able to take the transfer box off without removing the whole gearbox, you'd need to take the seat box out to get to some of the bolts and by that time you may as well remove the whole lump and make your life easier.  (it should take about 3-4 hours to remove the box if you've not done it before.) 

Thinking about it now, have you adjusted your handbrake recently?  As I can't really see what would be smoking inside the box and an over adjusted transmission brake smokes like a goodun.

There's a load of photos of the inside of the trasfer box http://ollr.10.forumer.com/viewtopic.php?t=3778 and gearboxes http://ollr.10.forumer.com/viewtopic.php?t=3133

ian_s:
drop the inspection plate off the bottom of the transfer box and see what its like inside
if it is knackered you should be able see damaged gears.

Singlefin:
Cheers for that guys, have started investigating...

Either it's not the transfer box that's [!Expletive Deleted!] but my overdrive, *or* my overdrive is [!Expletive Deleted!] as well... :doh:
I popped the overdrive off as a prelude to getting the xfer box off and found that it had about half a bean tin's worth of oil in it, as well as a bunch of twisted shimmy-looking things. Also, in the middle of the shaft, it looks like something yellow and plastic has melted. Thinking back to when I broke down, the transfer box was warm, but I actually burnt myself on the overdrive, so I'm choosing that as my prime suspect for now.
Wish me luck!

Lucy1978:
The yellow plastic is most likely the carrier for some roller bearings. similer to the ones used on the mainshaft.

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