Another transfer case noise. ..

[Rob king]

Hi again.
This one is not for me. I recently assisted a friend who liked my RRS so much he wanted one too. We found a well optioned 4.2 supercharged '07 with 170k km
The car runs well, smooth gears. No shudders, tight suspension... Etc.
After just 1 week however it has developed a scraping noise in the drive train.
It's speed dependent not revs. We lifted the car and spun the rear wheels since it did sound like brakes or a bearing. There was the noise, a scraping gravelly noise we could hear and feel right at the rear of the transfer box where it joins with the rear drive shaft.
On investigation we found there is a drive flange kit consisting of the flange, needle bearings and seals as an assembly. It links the tail shaft to the transfer case drive and from what I can tell it's where the sound is coming from, it would be logical if the needle bearings have collapsed.
Has anyone had this experience? Any other suggestions or diagnosis?
All advice welcome. I'm feeling partially to blame:(
Rob.

[shanegtr]

Drop the transfer case oil into a nice clean container and have a look for any excessive metal contamination

[Rob king]

Thanks Shane,
Yes we already checked that, and there is the usual metal flakes etc. which is disconcerting but from what I've read elsewhere that's pretty well normal.
The transfer will be flushed and oil is being changed ($80/litre)
I'll be doing mine too just in case!
This noise seems to be the bearing in the rear output flange.
The kit is part no LRO39528. We are dropping the prop shaft and removing the flange tomorrow, then will know for sure.
On the topic of contamination, I've also read that the transmission is far less likely to develop problems by fitting the modified sump and filter kit and then changing the fluid every 80k rather than the suggested 'lifetime' arrangement.
If so, it's not a difficult or expensive modification and I'd be keen to do that to mine as well. Anything to save the wear.. And possible future expense.
Rob.

[shanegtr]

If you need some photos of whats inside the magna steyr transfer case, have a look here:
Magna Steyr DD295 Transfer Box Teardown (http://www.rangerovers.net/forum/6-range-rover-mark-iii-l322/41233-magna-steyr-dd295-transfer-box-teardown.html)


Royal Purple list their syncromax oil as meeting the shell TF 0753 spec. That's what Im currently running in my D3 and its a hell of a lot cheaper than $80 a litre
http://www.royalpurpleconsumer.com/assets/2014_Royal_Purple_Transmission_Lubricant_Cross_Ref erence.pdf

[Rob king]

Thanks Shane,
That's an excellent reference and great advice.
I hope we don't need to go inside the case, but as most of the fear is in the unknown, it seems less daunting now.
Definitely worth picking up a spare to rebuild at the right price just in case.
Rob.

[justinc]

Rob don't feel bad the case likely has never had the oil changed we see heaps like that it seems everyone thinks these vehicles don't require servicing..😠. The case is actually very easy to remove and not difficult to disassemble. It is quite a stupid idea that in order to replace a simple output seal you need to disassemble the case as the seals are fitted from the inside 😠😠😠. Anyway they do a good job considering.

Jc

[Nomad9]

Hi Rob,
Same as shanegtr, I've been running RP Syncromax, diff oils and engine oils for about 10 years now with no problems at all. RP won't fix something that is broken it just stops things breaking in the first place.

Cheers Marty.

[Rob king]

Just a follow up.
The rear transfer output case bearing was rattly.
With the help of a friendly visiting puma owner and cane toad 'Muddy' we floated the car to a recommended indy at seven hills. Turns out the bearing would have made the trip but we weren't to know.
They have done hundreds of these. Mostly for LR dealers.
Aparently there has been a problem with the preload settings ex factory which causes premature bearing failure. (140-180k)
It's generally outside warranty though.
So a day in the shop, transfer bearing overhaul and good as new.
My mate was quoted 2260 drive in drive out to overhaul his box.
They only charged him 1500 since the work was less than allowed.
Can't fault their integrity.
Could have been far worse.
Thanks for all the advice Shane JC and Marty and to Graeme for his recommendation.
Rob.

[letherm]

Just a follow up.
The rear transfer output case bearing was rattly.
With the help of a friendly visiting puma owner and cane toad 'Muddy' we floated the car to a recommended indy at seven hills. Turns out the bearing would have made the trip but we weren't to know.
They have done hundreds of these. Mostly for LR dealers.
Aparently there has been a problem with the preload settings ex factory which causes premature bearing failure. (140-180k)
It's generally outside warranty though.
So a day in the shop, transfer bearing overhaul and good as new.
My mate was quoted 2260 drive in drive out to overhaul his box.
They only charged him 1500 since the work was less than allowed.
Can't fault their integrity.
Could have been far worse.
Thanks for all the advice Shane JC and Marty and to Graeme for his recommendation.
Rob.
Hi Rob.

What's the name of the Indy at Seven Hills? Sounds like he is one to keep in mind for any future work. Please PM me if you don't want to make it public.

Martin

[PeterOZ]

My D3 2007 has a distinctive "rumble" sound, comes in around 60 to 65, not noticable at higher speeds.


If you back off slightly on the throttle it goes away, more noticable just going up a slight incline with a tad of power on.


It was there though not that noticable when the vehcile was under both lease and warranty and desitote taking it to the dealer many times they could never hear it, even MR could not hear it though I bloody well could.


Any thoughts?

[jonesy63]

Hi Rob.

What's the name of the Indy at Seven Hills? Sounds like he is one to keep in mind for any future work. Please PM me if you don't want to make it public.

Martin

Martin,
I'm pretty sure it would be "Award Diff & Gear Box Services". I seem to recall they were mentioned here in the past, but can't seem to find any links.

[Rob king]

Hi Jonesy, yes I PM'd him.
That's them, see Terry.
His wife Trish is the office is also up to speed.
Regards
Rob.