Gearbox went bang!

[Summiitt]

Well, the one thing I didn't want to happen, has, took off from the lights in the rangie(hse td6 2004) and it made a bang under acceleration, it came out of high range, low range light started flashing and I lost drive...now it will change between high and low range, but makes a terrible noise. It sounds like the gears arnt meshing, I can select all gears on the gear lever but the noise starts up again. I have no drive in forward or reverse, high or low.
Anyone who has had their gearbox pack it in, what noises, symptoms occured?
The vehicle has had the gearbox oil changed, and only has 99,000km on the clock. My gut feeling is that the high low selector or the transfer case has sh#t itself rather than the gearbox? Any ideas?

[RangieBit]

Hmmm,

From your description there it does sound more like a transfer case/gears issue than the main gearbox as I don't recall ever hearing of significant grinding noises from a failed gearbox. I did hear of troubles with misaligned flange plates creating similar issues for the transfer case (loss of drive) when the gearbox had been removed and reinstalled. Others more knowledgeable than I may be able to assist here.

It's all very well to change the transmission fluid at regular intervals but just how much swarf was lying in the sump and/or in the filter when it was drained? The more of that there is, the more likely failure is. I know preaching to the choir there.

Good luck with it. I'll add my support on the transfer case side of things.

Over to the more experienced.

Cheers,
Iain

[101RRS]

Tim - that is really bad news - does sound like a tfr case - indeed sounds like my 101 or old Disco 1 jumping out of hi or lo range.

Canberra is not a place where you want something like that happening.

Good luck with it.

Garry

[Summiitt]

Cheers, would much rather it happen in Canberra than out bush, I'm heading out to do the border track in a few weeks time, that would be an expensive tow job!

[Scouse]

Has the front diff recall been done? Stripping the shaft splines results in a loss of drive & an awful noise.

If you're not sure, call your local dealer & ask them to check. They'll need your VIN.

[Summiitt]

Bit of an update on the broken rangie, it appears that the rear output shaft on the gearbox has stripped the splined going onto the input shaft on the transfer case. The transfer case is all but a throw away due to the damage done and it looks like the gearbox will need a full rebuild as it's suspected that the Main shaft is twisted, in any case a lot of dollars. Bugger!

[Summiitt]

Yet another update, looks like the initial cause of the whole failure, was a twisted mainshaft in the gearbox, which in turn destroyed everything south, has anyone ever heard of a twisted mainshaft in these boxes? Cheers in advance of your response.

[Homestar]

No - that's a new one to me. Normally failures of the trans is caused by valve body wear or torque converter failure due to lack of maintenance - I haven't heard of such a failure before, but others here might of.

I feel your pain - I hope you get it sorted with a minimum of fuss - it will be costly, but I hope it is less hassle than what I went through.

[Summiitt]

Thanks, have ordered a brand new transfer case and am sending the gearbox off on Monday for a full rebuild with guys who know what they are doing...only had the car for 2 months!! Will be interested to hear if anyone else has had this mainshaft failure...

[Homestar]

If it makes you feel any better, my trans went bang 2 DAYS after I bought it...

[Hoges]

Had the recall been done on the front drive shaft alignment?

[Homestar]

It has been on mine, not sure about Summiitt's.

[Summiitt]

Yep, front diff recall has been done...
2 days, bugger. As expensive as it is, you've just got to laugh...well try to at least!

[Homestar]

All you can do is laugh - it is the only thing that got me through our ordeal - quite a nightmare, but when you look back on it all, it is quite funny - you couldn't write a script like what happened to ours and think that anyone would believe it - just a comedy of errors on all parts from the get go. Once it is repaired, and you are driving it again, the bad times soon fade because they are such a great car to drive.

[Summiitt]

Finally got the rangie back today, brand new transfer case, fully reco gearbox and everything that goes with it, including a big invoice!
Thoughts are that the failure was due to an abused gearbox/ driving style due to the twisted mainshaft, apparently almost unheard of in those GM boxes, bit scary considering the car only has 100,000km on it.All oils had been changed and the gearbox had some service history.

[Laurie]

I haven't heard of the main shaft going on these boxes, but the output shaft twisting has been mentioned a lot in British forums and US Caddy, BMW forums. JPAT in the UK make a H/D replacement item:

http://www.jpat.co.uk/5L40E%20Shafts.pdf

Could this have failed ? and with the demolition of the transfer case the torque and pressure exerted back into the box twisted the main shaft ?

As a side note when they uprated this box to the 5L50E version they changed the number of teeth on the rear annulus gear, though post 03' boxes had the larger planetary gears and extra clutch plates found in the 5L50E. GM,LR and BMW knew they had a problem with this auto instead of a expensive recall they decided to do incremental updates by stealth and hope most would reach the end of their warranty.

[Summiitt]

For sure, initial loss of drive was due to stripped splines on the output shaft, then lots of damage to follow, as for the transfer box, they are almost a throw away as parts are hard to source, so a brand new out of the box one was installed. Thanks for the other info.

[milld]

I guess you didn't pay $120 for a second hand transfer case at the wreckers then like I did :P I think I might stick with my Classic :)

[Homestar]

I guess you didn't pay $120 for a second hand transfer case at the wreckers then like I did :P I think I might stick with my Classic :)

Yeah... The NV225 Transfer box in the L322 is a fairly complex bit of kit. I believe a new one would run to about $4K I think - not 100% sure. Summiitt would know, but that's up to Summiitt if he wants to share that with us.

[Summiitt]

Your close! Retail price as listed on the invoice is $7303! that's a genuine one with a new mounting kit which is required as the old mounting bush has to be replaced. Because I had the gearbox done as well, I got the transfer case and mount for a pinch under $4k.
I'm about to head over the brindabella ranges to Tumut, and it's raining, so I'm looking forward to giving it a good test!

[romar]

Thanks, have ordered a brand new transfer case and am sending the gearbox off on Monday for a full rebuild with guys who know what they are doing...only had the car for 2 months!! Will be interested to hear if anyone else has had this mainshaft failure...

who is doing your transmission & at that cost cheers Roger.

[Summiitt]

Ray at Canberra motor works in Mitchell, ACT did the job, but sent the gearbox off to somewhere in Melbourne as they are the gurus with those GM boxs, I didn't spare any expense in doing it right and upgrading to heavy duty parts wherever possible.