Mahindra uses a Dana 18 based transfer case with opposing output shafts offset from the input shaft. The 2 main differences are the Mahindra transfer case uses a separate input shaft that slides over a transmission output shaft, a Dana 18 uses an input gear that slides over the transmission output shaft; and the gear tooth profile angles are slightly different.
The Mahindra transfer case does share some components from Dana 18 however a majority are unique to Roxor vehicles. A low range ratio of 2.46:1 is shared between the two.
Roxor Transfer Cases are generally reliable and fairly easy to rebuild with only a few specialty tools required. We have found the #1 failure is due to fluid contamination, followed by failures that are too difficult to identify as metallurgy or abuse being the cause. A failure tied for second place is rebuilding the transfer case and incorrectly setting shaft shim tolerances.
When rebuilding your Transfer Case, using correct thickness gaskets and the correct shim pack thicknesses is critical. The factory front output housing gasket thickness will correctly place your high range drive gear in line with the idler shaft, and rear output housing shims will correctly adjust bearing preload or end play. The front input bearing shim will correctly secure the input shaft from fore and aft movement, as well as axial movement.
While input bearing and output housing shim tolerances are not clearly defined in various Mahindra service manuals, final end play for input and output shafts should be 0.003"-0.007". Our preference is as close to 0 end play as possible for speed limited severe duty industrial applications to limit shaft deflection; however, for all other applications, the gear configuration inherently generates alot of heat, and thermal expansion can be accounted for.
Roxor is the first commercially available 4 wheeled motor vehicle from Mahindra available in the US and Canada. It's roots started very similar to Jeep vehicles in the late 1940's, however the evolution path was much slower and quite a bit different than American produced vehicles.
Today, Roxor has a cross of new and old technology. Front disc brakes, a computerized fuel injection and emission system, and open knuckle front axle design are some of the modern equipment used. On the older side; drum rear brakes, 19 spline inner/10 spline outer axle shafts, and a model 18 clone transfer case coupled with 1310 driveshaft joints are the standard (and only) factory option.
