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Dongfeng Transfer Case

Dongfeng Transfer Case
Dongfeng Transfer Case
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What is the Dongfeng Transfer Case

  • The Dongfeng Transfer Case is engineered to reliably manage torque distribution between front and rear axles in 4WD/6WD commercial and off-road vehicles. This critical drivetrain component ensures optimal traction across diverse conditions through precision gear engagement and rugged construction.
  • Gear Train & Power Transfer Core:
  • Torque routing centers on the Power Transfer Gear, driven by the Transfer Case Shaft.
  • Dual idler gears – the Upper Idler and Lower Idler – mounted on the Lower Idler Shaft via a Slotted Spring Pin (6×50), ensure synchronized power flow.
  • Critical Sliding Gear engagement enables seamless shifts between drive modes.
  • Axial positioning is secured by Circlips (Shaft 30, Shaft 24), Front Spacer, Rear Spacer, and Locating Snap Ring 52/57.9.
  • Premium bearings handle radial loads: a Needle Bearing (4524906) supports idler motion, while Ball Bearings (304, 205) and the grooved Ball Bearing with Snap Ring Groove 50 ensure smooth shaft rotation.
  • Housing, Sealing & Lubrication:
  • The heavy-duty Transfer Case Housing encapsulates all internals.
  • Superior sealing is achieved via multiple O-Ring Seals (45×3.55, 15×2.65, 9×2.65), a critical Oil Seal (PG25×42×10) seated in its Oil Seal Seat, and a Combined Seal Washer.
  • Lubrication integrity is maintained by a dedicated Oil Drain Plug and strategically placed Spacer rings ensuring proper oil flow.
  • The Flat Key (C10×32) provides positive drive connection between shafts and gears.
  • Shift Mechanism & Control Assembly:
  • Gear selection is managed by the Rocker Arm and Shifter Peg, guided by Locating Plates and secured with Slotted Spring Pins (8×32, 5×32).
  • The Control Lever connects to the Pivot Shaft (fastened with M8×16 Hex. Head Bolt and Spring Lock Washer 8), transmitting driver input.
  • Precise gear positioning is ensured by the Positioning Plate, Steel Ball (10), and calibrated Spring within the Transfer Control Handle.
  • External linkages use Hex. Nut M12 with Spring Lock Washer 12 and Plain Washer 12 for secure mounting.
  • Precision Fastening & Reliability:
  • Internal components are secured with Cheese Head Screws (M5×16) and Spring Lock Washers 5.
  • A Straight Pin (A8×30) provides additional location security.
  • The Circlip for Hole 55 retains critical external assemblies.

Parameters of Dongfeng Transfer Case

No. Part No. Name Quantity
1 304.42.101 Power Transfer gear 1
2 GB1096-79 Flat key C10×32 1
3 GB65-85 Cheese head screw  M5×16 4
4 GB93-87 Spring lock washer 5 4
5 304.42.133-1 Locating plate 1
6 GB895.2-86 Circlip for shaft  30 1
7 304.42.104-1 Front spacer 1
8 GB5801-86 Needle bearing 4524906 2
9 304.42.105 Upper idler 1
10 304.42.103 Rear spacer 1
11 304.42.116 Spacer 2
12 GB305-89 Locating snap ring 52/57.9 2
13 GB277-89  Ball bearing with snap ring groove 50 2
14 304.42.117 Lower idler 1
15 304.42.118 Lower idler shaft 1
16 GB879-86 Slotted spring pin 6×50 1
17 GB119-86 Straight pin A8×30 2
18 304.42.109-1 Transfer case housing 1
19 12.37.149 Combined seal washer 1
20 200.38.024 Oil drain plug 1
21 GB276-89 Ball bearing 304 1
22 304.42.106-1 Sliding gear 1
23 304.42.107 Transfer case shaft 1
24 GB894.1-86 Circlip for shaft 24 1
25 GB276-89 Ball bearing 205 1
26 GB3452.1-82 O-ring seal 45×3.55 1
27 304.42.108 Oil seal seat 1
28 HG4-692-67 Oil seal PG25×42×10 2
29 GB893.1-86 Circlip for hole 55 1
30 304.42.012-1 Shifter peg 1
31 GB879-86 Slotted spring pin 8×32 1
32 GB879-86 Slotted spring pin 5×32 1
33 GB3452.1-82 O-ring seal 15×2.65 1
34 304.42.111 Locating plate 1
35 304.42.013-1 Rocker arm 1
36 GB93-87 Spring lock washer 8 3
37 GB5783-86  Hex. head bolt M8×16 3
38 GB6170-86 Hex. nut M12 2
39 GB93-87 Spring lock washer 12 2
40 GB97.1-85 Plain washer 12 1
41 GB3452.1-82  O-ring seal 9×2.65 1
42 304.42.113 Pivot shaft 1
43 304.42.014-1 Control lever 1
44 GB96-85 Plain washer 12 1
45 304.42.134 Transfer control handle 1
46 304.42.115 Positioning plate 1
47 GB308-84 Steel ball 10 1
48 304.42.114 Spring 1

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