luciogodoy wrote:

Hi All;

I've decided to do an oil change on my D3 Transfer Box, and have taken some pictures along the process.

It is fairly easy and very quick, costs less than £60.

Parts list:
2 x YK500010 - Special Transfer Box Oil (Sold as 1L bottle, you'll need 1.5L) £42.82 + VAT (£21.41/L)
2 x YF500030 - Cooper washer £1.16 (£0.52/Unit)
Roughly 70cm of 18mm clear pipe (read on it will make sense)
Roughly 5cm of 15mm cooper pipe (read on it will make sense)

Tool list:
1 x 8mm HEX socket
1 x transparent plastic jug with measurement
Old newspaper and plenty of rags
16mm drill bit (read on it will make sense)
electrical tape or similar
Jack/Ramp/Axle stands (Whatever is your method to lift the car)

Procedure:
1 - Warm up the car, so the transfer box oil isn't too thick
2 - Park the car on a flat surface and raise the suspension to off-road
3 - Put parking break on and gearbox on "P", then switch off the engine
4 - OPTIONAL - raise the car



5 - Locate the filling bolt, and remove it,



6a - Locate the transfer box "sump" bolt and remove it - make sure you have covered the ground with newspaper, and that you are holding the plastic jug underneath the bolt you are undoing it, as oil will go everywhere!! You've been warned



6b - This is what came out from my transfer box, 1.4L of dark oil but no bits of metal on it.



7 - Old and new oil:



8 - "Things" to make the filling bottle, cut the plastic pipe around the 70cm mark



9 - Thickness of the plastic pipe,



10 - Using a kettle, boil some water, dip the plastic pipe on the hot water for few seconds to soften it, and then insert the copper pipe to that end.



11 - Remove the oil lid, and with the 16mm drill bit, drill a hole on the top of it, it is easier to make the hole from inside out, make sure you don't damage the plastic threads, as you need to screw it back!





12 - Using the oil bottle as reference, measure how much you need to insert the plastic pipe inside the bottle, and use a bit of tape to make sure when you insert the pipe, there is no leaks!







13 - Prepare the second bottle by marking the half litre point, and also make sure the second bottle is readily available near you when you are underneath the car,



14 - So at this point, the transfer box should be empty, switch the old cooper ring with the new ring you purchased, and close the drain plug (not sure of the torque, I've tightened by hand, I've seen other people ruining the thread by over torquing it),

15 - Using the "high tech" bottle, insert the copper pipe on the filling hole, and start squeeze the bottle, remember the bottle does not need to be upside-down on my (if you followed my design), when finished, change the bottle, making sure you only add the 1.5L back on to the transfer box,



16 - if you add too much oil, the excess will drip from the fill hole, when you are happy, close the fill hole using the new washer, and job done!

17 - Take the car for spin, and enjoy it.