Thread: Help needed. 93 200tdi transfer box.

It may have stripped the splines on the gearbox mainshaft.

Get the mechanics to pull the inspection plate on the back of the transfer case (round plate with 6 bolts) to check.

If this is the problem then you will need to source a new gearbox - reco or SH.

Hopefully it is something less serious though.

Originally Posted by isuzurover

It may have stripped the splines on the gearbox mainshaft.

Get the mechanics to pull the inspection plate on the back of the transfer case (round plate with 6 bolts) to check.

If this is the problem then you will need to source a new gearbox - reco or SH.

Hopefully it is something less serious though.

I agree - however I believe the splines in the spudshaft wear a little quicker than those on the geabox/tfr shafts so the splines on the spudshaft might be the culprit in which case it can be replaced in situ to at least get the vehicle on the road. However the gearbox splines will still be in poor condition and will have to be replaced shortly after as outlined by Isuzurover. As he indicated you need to take that cover plate off and pull the spud shaft out and check what is what.

Before that though - see if the tfr case will engage at the transfer case with the linkage removed - at its simplest it could just be an adjustment issue even if all moves as it should - maybe restricted range.

Garry

if you are incredibly lucky it will be the selector for high/low range jumped off or worn out the check you want to do is

remove the back access port (its roundish)
jack up a front wheel,
kick the front wheel around while looking in the hole youve opened up while someone actuates the high/low lever
if you see the gear turning and it changes speed then its most likely the spud shaft or the gear splines
if you dont see the gear turning or changing speed then its the selector mech.

Sorry to say that the 2 problems (the spud shaft and gear splines) are far more common than selector failure.

Thanks all for the replies. It sounds like we are extremely lucky and an adjustment screw on the selector collar for high low had loosened off. That's the story the mechanic just told us anyway. Hopefully it's fixed and we're off again in a few hours.
Thanks again for all the help!

There's quite a few guys in Albury (well Wodonga) that know their **** - on this forum you will see a section that says 'North East Vic' - post in there and you should get an answer.


Cheers
Chris

So the transfer box has bigger issues than just the selector grub screw. It got him to Margaret river but today it popped out and is having all kinds of troubles. He's hoping to get a tow to Perth tomorrow and was wanting to ask the aulro brains trust what recommended mechanic to have it towed to. Also if anyone knows of a good place to get a second hand or reco transfer box that would be great.
Thanks!

Originally Posted by gitney

So the transfer box has bigger issues than just the selector grub screw. It got him to Margaret river but today it popped out and is having all kinds of troubles. He's hoping to get a tow to Perth tomorrow and was wanting to ask the aulro brains trust what recommended mechanic to have it towed to. Also if anyone knows of a good place to get a second hand or reco transfer box that would be great.
Thanks!

(I am assuming the vehicle is a defender rather than a disco (as this is the defender section))

Kev at Jordan Rover Tech (Bentley) may be the best option.

As for a reco transfer case, Rovacraft stock Ashcroft reco t-cases but usually want an arm and a leg for them.

Linnrover may have a good second hand one, but you may be forced to fit a disco (1.2:1) instead of the defender 1.4:1 case. It would be driveable, but would make the car a slug on the highway.

If he isn't in a hurry he can probably air freight a t-case direct from Ashcroft in under a week for less than Rovacraft charge.