Transit Maintenance Combined Gearbox/Transfer Box/ Front Diff  I'd been getting intermittent fault warnings, the Yellow Spanner and "AWD Malfunction Service Required" on the dash display. The Diff Oil Pressure sensor fell apart when I removed its electrical connector to access the Haldex reservoir.  On closer inspection, you can see Glue around the base of the protruding female socket. I soon found out why someone had repaired it, these sensors cost £300 (Sep 2025). Its easy to get at, so a DIY job to replace. PartsPlus part number: F2267767 Description: CAL204536 SENSOR ASY - PRESSURE. It was worth the cost, as the intermittent fault light and dash warning I used to get, went away. While I was at it, I changed the Gearbox oil and combined Diff/Transfer Box oil, so this should see me through for the time I own the van. MT82 Gearbox and diff/transfer box lubrication.  This picture is from the Service manual. Note the instruction at the bottom for the correct fill/level on the Gearbox. So 3.35L into the Right side of the gearbox and 0.9L into the Left when doing an oil change. Also note that the Gearbox and combined Diff/Transfer Box use different grades of oil. The type and Qty of Oil for the Gearbox changed after 25th March 2021. For the above Oils: Combined Front Diff/Transfer Box Ford Transmission Oil 75W ISC Spec: WSS-M2C200-D3 Diff/Haldex Small Reservoir Gearbox up to 25th March 2021 Build date.  The Gearbox drain plug is located underneath, in the middle of the rear section of the box.  The Gearbox filler plug is on the right side of the box near the prop shaft. First, fill to the lip of this hole (Approx 3.35L) and re-fit the plug.  Second, it requires an additional fill. Remove the plug on the Left side of the box, add an additional 0.9L and refit the plug.  The front differential and transfer box share oil and have a common drain plug. This is located on the left side of the diff at the lowest point. The diff is located at the left side of the g-box bell housing.  The diff/Transfer box filler plug is on the front face of the diff housing, just below the engine oil filter. Fill with oil to the lip of this hole (Approx 2.1L). Note, this oil is expensive at £87.23/L (Sep 2025). Additionally, there is a small qty. of this oil (150mL quoted in service manual) in the reservoir, located above the oil pressure sensor, on the Left side of the front diff. (See Picture below). Remove the two bolts on the plastic cap, then top up if necessary, to the ridge near the top edge, where the internal diameter changes. It only took 100mL to completely fill mine after loosing the contents, when changing the Haldex pressure sensor mounted below it. Tip: Its easier to do this with the road wheel removed and the Pump/Sensor harness unclipped and moved over the drive shaft. Also a mirror on a stick helps see into the chamber to check the level.  |
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