Thread: Perentie 4x4 transfer issues

Personally, I'd be using 20W50 oil in the gearbox/transfer case. I tried using a lower weight oil and wasn't happy with it.
Hearing your issues, I wonder if the lower weight oil caused my oil migration problem.

The oil migration problem is best fixed by replacing the seal. It has been discussed before in other threads on this problem. I'll see if I can find them.
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.

Drained the transfer case oil, dark brown colour, minute flexs of copper coloured metal, I assume brass? I have kept a sample to settle overnight. No ferrous fragments, I tested with a magnet.
Would that indicate thrust washers????
Does the centre diff have them as well??
Hope this helps the brains trust here give me more advise.

Thanks,

Originally Posted by Phil B

Drained the transfer case oil, dark brown colour, minute flexs of copper coloured metal, I assume brass? I have kept a sample to settle overnight. No ferrous fragments, I tested with a magnet.
Would that indicate thrust washers????
Does the centre diff have them as well??
Hope this helps the brains trust here give me more advise.

Thanks,

Could be the thrust washers or the washers for the spider gears in the centre diff. They're the only bits I can think of but I've never had one of these gearboxes apart. Are the flecks of significant size? I usually get flecks of metal when I change the oil.

Originally Posted by Mick_Marsh

Could be the thrust washers or the washers for the spider gears in the centre diff. They're the only bits I can think of but I've never had one of these gearboxes apart. Are the flecks of significant size? I usually get flecks of metal when I change the oil.

Thanks for the response Mick.
The fleck are very small and give the oil a copper tinge in sunlight. Definitely visable though.

Regards,

Well, I get the same but only silver in the 100" and the Perentie but they are both TRB.
I don't do enough km in the 101s so I couldn't tell you what the oil was like.

You should also have a TRB in you Perentie so no thrust washers in the transfer case. That leaves the centre diff spider gears. I can't see how that would be causing the transfer case to be dropping out of gear.

Phil it is going to be one of two things. Sounds like you have read previous threads on this issue so I think you will know what I am going to say. It will be either the lever fouling on the insulation under the gearstick boot or wear on the intermediate shaft itself which the hi and low range gears sit. Check the insulation bit first and if you are sure the lever is engaging the gears correctly then drop the sump off the transfer case and have a good look at the intermediate shaft gears. In particular check if the gears have any lineal movement. They should be firm and have no play in between them and also check the engaging dogs on both range gears. The teeth should be straight and not be tapered on the end that faces the selector gear (in the middle). Get someone the move the gear lever while you are under looking at it and see what is happening. Is it possible that the transfer may have run low on oil with your migration issue ? If so it is possible that the forks that move the selector gear may have worn from friction and now have a large gap which is preventing the forks from moving the selector far enough to fully engage the gear. It should be only be about .005mm gap between the rear selector fork and the gear face with the lever in neutral. The brassy look in the oil will be from the brass thrust washers behind the bevel pinions in the centre diff. Pretty normal but check for play in the centre diff while you are at it - you may have to reshim it. The centre diff bolts should be loctited and the only way to check is to take the rear output housing off and remove one of the bolts and check for loctite residue. Both the low range bolts and the ones that bolt the two halves together should be loctited. The migration issue can be fixed by loctiting the distance sleeve and output gear on the rear of the mainshaft. Also worth putting a welsh plug into the reverse gear shaft hole in the transfer as this is another known oil migration spot but this one transfers from the gearbox to the transfer case. Let us know what you find.

Originally Posted by Bearman

Phil it is going to be one of two things. Sounds like you have read previous threads on this issue so I think you will know what I am going to say. It will be either the lever fouling on the insulation under the gearstick boot or wear on the intermediate shaft itself which the hi and low range gears sit. Check the insulation bit first and if you are sure the lever is engaging the gears correctly then drop the sump off the transfer case and have a good look at the intermediate shaft gears. In particular check if the gears have any lineal movement. They should be firm and have no play in between them and also check the engaging dogs on both range gears. The teeth should be straight and not be tapered on the end that faces the selector gear (in the middle). Get someone the move the gear lever while you are under looking at it and see what is happening. Is it possible that the transfer may have run low on oil with your migration issue ? If so it is possible that the forks that move the selector gear may have worn from friction and now have a large gap which is preventing the forks from moving the selector far enough to fully engage the gear. It should be only be about .005mm gap between the rear selector fork and the gear face with the lever in neutral. The brassy look in the oil will be from the brass thrust washers behind the bevel pinions in the centre diff. Pretty normal but check for play in the centre diff while you are at it - you may have to reshim it. The centre diff bolts should be loctited and the only way to check is to take the rear output housing off and remove one of the bolts and check for loctite residue. Both the low range bolts and the ones that bolt the two halves together should be loctited. The migration issue can be fixed by loctiting the distance sleeve and output gear on the rear of the mainshaft. Also worth putting a welsh plug into the reverse gear shaft hole in the transfer as this is another known oil migration spot but this one transfers from the gearbox to the transfer case. Let us know what you find.

Bearman,

Thanks for your very detailed response, it is really good and exactly what I needed.
I will inspect all the items you have mentioned this weekend and report back. Hopefully it is the lever fouling the insulation.
Yes it did run low on two occasions and required 750ml to refill. When I drained the oil this week it was about 100ml low.

I will let you know what I find.

Thanks again.

Originally Posted by Mick_Marsh

Well, I get the same but only silver in the 100" and the Perentie but they are both TRB.
I don't do enough km in the 101s so I couldn't tell you what the oil was like.

You should also have a TRB in you Perentie so no thrust washers in the transfer case. That leaves the centre diff spider gears. I can't see how that would be causing the transfer case to be dropping out of gear.

Thanks for the response Mick,

I will investigate further this weekend and let you know what I find.
I have a detailed response from Bearman as well which I will investigate.

Regards,