I think I need to get the power transfer unit looked at as I have a loss of drive to the rear wheels and when I turn the prop shaft it spins freely in hand. Question here is, assuming It is in need of replacement is it a job for a diy’er? I’m handy with the tools but I’ve not attempted anything like this before. I hear of people changing them but not seen any write ups or photos of the process. Can anyone here help? Also, if I go for a reconditioned unit is it best to go for the bell Engineering unit that has hardened splines despite the added expense?

See the thread called “Auto box comparison” by Andy 131

http://www.freel2.com/forum/topic26133.html

Bob 10MY (Sept 09) TD4 HSE Auto in Stornoway Grey (Now Gone)

08 FL2 TD4 SE Manual in Rimini Red (Now Gone)

Doesn’t have any instruction or tips for how he did it, just says that he did.
Someone must have completed this themselves and is willing to lend a hand.

Andy 131 has made a detailed description of removing the transfer box and replacing the splined drive. Now you know that, it is your turn to do a search....

Bob 10MY (Sept 09) TD4 HSE Auto in Stornoway Grey (Now Gone)

08 FL2 TD4 SE Manual in Rimini Red (Now Gone)

Look for how2`s for a clutch replacement. The job involves removal of the PTU prior to removal of the gearbox. Migth be some hints there. Same applies to the Haynes manual. As far as I know, the PTU shall be replaced when the splines has worn out as its not only the splined sleeve that wears. Contact Bell engineering about this.

I purchased an exchange PTU from Bell Engineering and fitted it myself following the aforementioned guide. Not the easiest job but should be within the capability of a competent DIY mechanic, just make sure you have everything that you will need before you start!