Broken Down In Argentina / MAN Transfer Case - Help Please

[DavidQ]

Dear Community,

MAN TGM 13.290 4WD / Transfer Case G102 Z

We were driving down a dirt track in Argentina when the Transfer Case (TC) front drive shaft and propshaft came out of the TC. It flailed around a bit before we stopped but did not cause critical damage (exhaust pipe suffered most).

I disconnected the rear prop-shaft at the differential (strapped it up), disconnected the input prop-shaft at the gearbox (strapped it up) and removed the front prop-shaft. The police then towed us to a small town, which is where we are now (stranded).

I dissembled the TC front drive shaft housing and determined that the principle damage was to the front drive shaft housing (broken casting where the oil seal sits and the nose of the front drive shaft.

I have two specific questions I would like specific answers to please. These are:

It is my intention to continue with RWD only. I have disassembled the TC front drive housing and sealed the opening for the front drive shaft. I will reattach the housing, fill with oil and test.

Looking at the G102 Z parts diagram - the nose of the front drive shaft has a needle roller bearing cage that sits inside the TC internal gear. I am assuming the internal gear supports front drive shaft - and not the other way around. In other words I can drive RWD without the front drive shaft in place. See photo.

Q1: Can anyone knowledgeable of the TC G102 Z confirm that it is OK to run the TC in RWD without the front output shaft in place?

It is likely I'll need a new TC as MAN is doubtful I can buy the necessary parts (MAN is checking). A new TC is expensive. However I have an offer for a reasonably priced G103 Z. All of the MAN documentation I have access to show them to have the same specification.

Q2: Can anyone give me a definitive answer to whether a G103 Z can be used in place of a G102 Z, or if not, the difference between them?

Thank you so much
David
San Antonio de los Cobres, Argentina

[Sirjan]

Hi David,

to answer your question about the to different types:
Both transfer cases are the same externally. The difference is, that the 102 is permanent and the 103 is the non permanent type (with engageable front axle)
103 is lighter due to the missing differential gear, so the 103 behaves like a locked 102 when you engage it

If you lock the 102 and seal the front output shaft, you should be good to go as a temporary solution.

Personally, I would shift to the 103, the effect is the same and you safe around 10kg of weight ;-)

Regards,
Jan

[DavidQ]

Hi Jan,

Thank you, Having spent a lot of time researching and having obtained the workshop manual, I can confirm:

G102 has no neutral position. G103 has a neutral position.

The Z means engagable front wheel drive (no differential).

P means permanently engaged with differential.

The G103Z is not compatible with G102Z - it has an extra airport (neutral) and one of the feedback switches is opposite sense (NC not NO).

Dave

[DavidQ]

In response to my Q1, the answer is Yes. I blanked the front drive shaft and am driving in RWD. Dave

[lura]

Thank You for information. Did You find a place to repair the transfer case?

[Pirx]

The G103Z is not compatible with G102Z - it has an extra airport (neutral) and one of the feedback switches is opposite sense (NC not NO).

Peanuts!
This means 10 minutes of extra work to install the G103Z instead of the G102Z in your truck.

Pirx

[DavidQ]

Hi Pirx,

I couldn't risk exporting the G103 from South Africa to Chile and experiment. You are probably right, but the risk was too great for me.

David

[DavidQ]

Hi Bernd,

I've got the parts coming from Germany for delivery in Chile (import into Argentina is difficult). I will go to MAN Calama and ask them to help me reassemble my transfer case.

Dave

Story so far here:

https://catch-the-wind.com/we-broke-down-again/

[lura]

Hi Dave, I think about to transfer my MAN to South Amerika for a trip there. I'm really not sure,it is a good Idea.
Good luck for Your project.

[RainerKraft]

Hi Lura, we can only recommend that your truck and you come to South America - it’s more than worth!

Hi Dave, thanks for sharing - good luck on the repairs. Keep fingers crossed.

Rainer and Sandra (with some overheating Portal axis issue) one the jump from Bolivia to Brazil - RN 9 is a real wonderful adventure - like BBC documentaion - but live