110 Slipped out of 4H while coasting

[Devans]

Hi guys,

When I was driving on the highway down south last night my 96 110 "slipped" out of 4H and into neutral whilst coasting down a hill at around 90km/hr. It did it again today in the same circumstances.

Took me a while to figure out what had happened while on the side of the road at 11pm last night freezing my ass off.

Does anyone know why this happened or how to stop it from happening again??

Thanks!

[Rurover]

Devans,

I suspect the adjustment on your transfer case lever is out of whack.
If the adjustment is wrong, then the transfer gears don't fully lock into position and can be jolted out of gear when you change from the engine driving the wheels to the wheels driving the engine (as happens when you go down hill and ease off the throttle).

To do the adjustment, you'll need to remove the gearbox cover (which is a bit of a chore) in order to get to the linkages. BTW, I suggest you remove the top cast aluminium plate where the linkages articulate and lubricate all the bits while you have the cover off.

Good luck,

Alan

[tack22250]

hello all
just rebuilt lt 230 in my 97 130 tdi and same problem jumps out of hi range on a trailing throttle from as low as 20 kph 2nd gear have checked linkages has new selector hub and hi (diso ratio),input gear,intermediate gears (was a catastrophic failure) one piece diff centre pin all parts from ashrofts,suspect dogs are not square/undercut? enough, float was set as per manual as were all preloads etc need help as I need to drive it from Perth to northern NSW in a couple of weeks. Contacted dave at Ashcrofts and only got recheck linkages so I pulled the cross shaft cover off and levered off the case directly on the fork shaft ( yes very rough but am getting desperate)no different.?Any ideas appreciated.

[Ancient Mariner]

Have you checked the indent ball and spring on the selector shaft ?

[tack22250]

yes checked and adjusted but don't believe that this assembly should be taking all the load from back torque (to use a motorcycle term for want of something better) the back side of the engagement dogs should work the same way as the front to the best of my limited knowledge and some info from mechanic mate. when backing off the throttle and holding onto the range selector lever you can feel the gear getting loaded up and then letting go? I asked ashrofts about shimming/nut preload and got a maybe but can't tell with out examining it bit hard from the other side of the world told them no expectations of their recommendations or liability but they didn't seem interested whih is unusual as they are generally very helpful,mind you I have been plaing orders for 6oo pounds at the time!

[Devans]

hello all
just rebuilt lt 230 in my 97 130 tdi and same problem jumps out of hi range on a trailing throttle from as low as 20 kph 2nd gear

Okay, yours sounds worse than mine, mine only happens in 5th at about 90km/hr.

Hopefully this doesn't get worse whilst this gets figured out.

:(

[tack22250]

hey Devans
How many Km's has your box got on it? Maybe your selector hub/hi gear dogs are wearing/worn, if you haven't done anything to change linkage length or setup then it seems logical (unusual for me) to suspect some form of wear and tear. Do you do much towing? lots of down hill coasting?anything that would load up/wear the trailing side more than regular road driving? Just some thoughts that might help I hope.
Brett

[Devans]

hey Devans
How many Km's has your box got on it? Maybe your selector hub/hi gear dogs are wearing/worn, if you haven't done anything to change linkage length or setup then it seems logical (unusual for me) to suspect some form of wear and tear. Do you do much towing? lots of down hill coasting?anything that would load up/wear the trailing side more than regular road driving? Just some thoughts that might help I hope.
Brett

It's done 300,000kms… Pretty long life. I've decided when I have the coin to get a rebuilt gearbox and transfer case and stick those in. I'll keep the old two and rebuild them for if I need another or sell it on to someone who needs one.

It's not a huge problem for me at the moment, it's only happened twice, but I don't have the ability to drop the gear box and transfer at this stage, so looking inside isn't really an option unfortunately.

Thanks,
Dave