Perentie 4x4 transfer issues

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I did a temporary work around about twenty years ago that is still in place. Replace the level plugs with barbs and run a pipe (rubber hose) between them.

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I did the same and I think it is still under the house.
The only addition I would suggest is to solder the opening of the nipple , then drill with a small jewelers drill, maybe 0.5 mm or smaller.
That way the gearbox oil does not run into the transfer on steep hills.

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Originally Posted by Phil B

I have it in pieces and will have it check by a pro this week as I can’t see anything wrong. No play anywhere that I can see. I’ll report back

Bear man, the distance sleeve is free spinning as you suggested causing the oil migration. I am going to fix that while the box is open.
Which loctite should I use in between the shaft and sleeve?
Also which loctite on the diff bolts ?
Thanks again
Phil

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243 is fine but make sure you clean and prime everything before applying the Loctite. Also before you pull the gear off the end of the mainshaft to loctite it and the distance sleeve it is VERY important to put the gearbox in 3rd gear first, otherwise you will have trouble getting it all back together.

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Originally Posted by Bearman

243 is fine but make sure you clean and prime everything before applying the Loctite. Also before you pull the gear off the end of the mainshaft to loctite it and the distance sleeve it is VERY important to put the gearbox in 3rd gear first, otherwise you will have trouble getting it all back together.

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Thanks Brian, will do.

A report back on the transfer issues:

The transfer case intermediate shaft and its gears etc is now at KLR and they report that the main bearings in the cluster on the shaft have started to wear causing the noise on overrun.
They believe that the pre load or end float (too technical for me!!) may not have been correctly set up when the box was re furbished by the ADF years ago. The additional end float caused by the bearing wear has now caused the jumping out of high range.
The spacer on the main gear box output shaft is not loctited as Brian predicted and is causing the migration.
The copper coloured oil is from worn diff shims, possibly caused by not using the diff lock enough on my last trip.

The intermediate shaft, gears and bolt and the main gear and shaft are thankfully all servicable.

KLR are rebuilding the intermediate shaft cluster as well as the CDL and I will very carefully remove the main shaft gear and loctite the spacer this weekend before replacing all the parts.

I am quite relieved that I now know what has caused the issues and that essentially the transfer box will now be completely refurbished and hopefully last for years to come.

By the way I did check for interference to the lever and linkages and found that the foam was missing and the linkages need some oil but are otherwise OK.

Thanks again for everyones help.

Regards,

Thanks for the report back, Phil.

More news on the transfer box

On closer inspection the intermediate gears are pitted (suspect it stood for a while with the ADF when it was inoperable).
Replaced them (good used) and the gear box output gear (new),diff shims, bearings and main intermediate bolt.
All put back together by KLR (thanks for the outstanding service Brad).
I re-installed it all yesterday and left it overnight for the loctite on the spacer and main gear to go off (overkill I know but it’s cold!!)
Drove her this morning and all appears well!
Very pleased. Took about 6 hrs ( no ramp or hoist at home) and about $1600 all up.
Difficulty level medium (for me) except the main shaft spacer, gear and circlip which is a PITA.
No special tools required.
Phil