BFX160 Compound Transfer Case Repair Kit

1

O-ring

80x2.65

Nitrile Butadiene Rubber (NBR) 70 Shore A; excellent oil resistance and flexibility

1. Long-term exposure to high-temperature transmission oil causes rubber aging and hardening; 2. Installation misalignment leads to uneven compression and localized wear.

1. Ensure installation surface is clean and free of burrs; use proper installation tools to avoid stretching the O-ring; 2. Use only transmission fluids compatible with NBR material to prevent chemical degradation.

2

O-ring

85x2.65

Nitrile Butadiene Rubber (NBR) 70 Shore A; enhanced tensile strength for high-vibration environments

1. Continuous vibration from heavy-duty operation causes fatigue cracking; 2. Contaminants (dust, metal particles) embedded in the sealing surface abrade the O-ring.

1. Inspect and clean sealing grooves regularly to remove contaminants; 2. Avoid over-compression during installation—maintain compression ratio within 20-30% of the O-ring’s cross-sectional diameter.

3

O-ring

140x2.65

Nitrile Butadiene Rubber (NBR) 70 Shore A; low compression set for long-term sealing integrity

1. Thermal cycling (alternating high/low temperatures) leads to rubber fatigue; 2. Improper storage (exposure to sunlight/ozone) prior to installation degrades material properties.

1. Store O-rings in a cool, dark, ozone-free environment before use; 2. Allow transfer case to cool to ambient temperature before installing to avoid thermal expansion-induced misalignment.

4

Shaft Sealing Ring

B150 x 180 x 15

FKM (Viton) with stainless steel reinforcement; high-temperature (up to 200°C) and chemical resistance

1. Shaft surface scratches or corrosion damage the seal lip; 2. High-speed shaft rotation generates excessive heat, accelerating seal wear.

1. Inspect shaft surface for scratches/corrosion; polish or replace shafts with surface roughness exceeding Ra 0.8μm; 2. Ensure proper lubrication of the seal lip during installation to reduce initial wear.

5

Oil Sealing

B100*125*12

Polytetrafluoroethylene (PTFE) lip with nitrile rubber body; low friction and high wear resistance

1. Contaminated oil (with metal particles) causes abrasive wear of the PTFE lip; 2. Shaft axial play leads to repeated lip deflection and fatigue.

1. Regularly replace transmission oil and oil filters to keep oil clean; 2. Check and adjust shaft end play to within manufacturer-specified limits (typically 0.05-0.15mm).

6

Oil Sealing

B25x47x7

Silicone rubber with carbon steel housing; excellent low-temperature flexibility (-40°C to 180°C)

1. Cold start-up in low-temperature environments causes rubber brittleness and lip damage; 2. Over-tightening of the seal housing distorts the seal lip.

1. In cold climates, pre-heat the transfer case before start-up to avoid brittle failure; 2. Torque the seal housing bolts to manufacturer’s specifications using a torque wrench to prevent distortion.

1

Bearing

30316

High-carbon chromium bearing steel (GCr15); carburized and quenched, hardness HRC 60-64

1. Inadequate lubrication leads to metal-to-metal contact and raceway pitting; 2. Shaft misalignment causes uneven load distribution and edge loading.

1. Use high-quality lithium-based grease with NLGI Grade 2, ensuring 30-40% filling rate in the bearing cavity; 2. Check shaft concentricity during installation; correct misalignment exceeding 0.05mm.

2

Bearing

30317

High-carbon chromium bearing steel (GCr15); precision ground raceways for low friction

1. Contaminants (dust, metal particles) entering the bearing cause abrasive wear; 2. Shock loads from sudden acceleration/deceleration damage rolling elements.

1. Install effective dust shields and ensure proper sealing of the transfer case; 2. Avoid sudden full-load acceleration; operate the transmission smoothly to minimize shock loads.

3

Bearing

32216

GCr15 bearing steel with molybdenum disulfide coating; enhanced wear and corrosion resistance

1. High operating temperature accelerates lubricant degradation and bearing wear; 2. Axial overload exceeds the bearing’s design capacity, causing raceway deformation.

1. Monitor transfer case temperature during operation; avoid prolonged operation above 120°C; 2. Ensure the transmission system is properly adjusted to prevent axial overload on the bearing.

4

Bearing

352216

GCr15SiMn bearing steel; high tensile strength and impact toughness

1. Improper installation (hammering directly on the bearing ring) causes raceway damage; 2. Lubricant contamination with water leads to rust and pitting.

1. Use a bearing press for installation; avoid direct impact on bearing rings; 2. Check for water ingress in the transfer case regularly; replace lubricant if water content exceeds 0.2%.

5

Bearing

6009

GCr15 bearing steel; deep groove design for radial load capacity

1. High-speed rotation generates excessive heat, leading to lubricant breakdown; 2. Shaft runout causes uneven wear on the raceway.

1. Ensure adequate lubrication for high-speed operation; select lubricants with appropriate viscosity index (VI > 140); 2. Check shaft runout with a dial indicator; limit radial runout to ≤ 0.03mm.

6

Bearing

32028

GCr15 bearing steel; tapered roller design for combined radial and axial loads

1. Incorrect preload adjustment causes excessive internal friction and overheating; 2. Wear of the bearing seat leads to misalignment and uneven load distribution.

1. Adjust bearing preload according to manufacturer’s specifications (typically 0.02-0.05mm axial play after preload); 2. Inspect bearing seat for wear or deformation; replace if fit tolerance exceeds H7.

7

Bearing

32026

GCr15 bearing steel with nitride surface treatment; improved fatigue resistance

1. Repeated cyclic loads cause fatigue failure of the raceway; 2. Contaminated lubricant accelerates wear of rolling elements and raceways.

1. Regularly inspect bearing condition (vibration, temperature, noise); replace at the first sign of fatigue; 2. Follow a strict lubrication maintenance schedule, replacing oil/ grease at recommended intervals.