Low transfer case oil=rear diff failure??

Thanks heaps for the advice. I will definitely do all that tomorrow after work. To be honest when I removed the TC cover the gears looked alright, oil wasn't great but what can you expect from 30k since last change. I was thinking of going to the shop where I got the diff done and asking them; they said the diff ( which was the whole assembly) came out of a d2 with 60k. I have cdl so that's good. My only worry is that the clunking is what happened before my last diff went. I've had the car for 2 years and prior to that there wasn't any backlash but it got progressively worse since I noticed it.
Again thanks for the info and I will let you know the results. I hope it's the uni joint as I want to upgrade my prop shafts anyways.Oh and I thing it may be coming from the rear output seal. Had a look at urban panzers site and he had a leak almost in the same position as mine. Once I figure this issue out I will move to the leak(s)

Ok. Rear wheel with hand brake only get slightly did it move left and right, no prop shaft movement. Front with CDL engaged in park exactly the same, in drive there was a little bi more movement but still no front prop shaft movement.
With CDL disengaged in drive there is full movement with drive shaft spinning; which I think would be normal because the front isn't locked at all and TC isn't disabled. So from what I understand does this mean TC box ok and I should be looking elsewhere for my clunks/backlash. I am taking it back to the diff shop I had it at 2 months ago and they will have a look. FYI, there is oil on my right rear wheel hub and a little on the left, I read a little but not quite sure if it could be related to rear diff problems.
Thanks in advance for your comments and suggestions.

The bronze in the TC will be the centre diff shims (or remains of them) They are cheap enough to change (get a complete TC rebuild kit from Ashcrofts.) They are not that hard to do.

It will look like this inside most likely - the longer you leave it the worse it will get:

http://www.aulro.com/afvb/technical-...ff-damage.html

There is no link in the damage between the diff and TC

Thanks for the link and the informative post. I will have a look at the centre diff tomorrow after I take it to the shop. I will post a pic and hopefully you or somebody will be able to tell me if anything is wrong in there. Can it be diagnosed without removing or are the shims hidden away? Thanks

Hi Trevor,

i just wrote a farly long reply and my Internet explorer crashed!

When you get the Centre diff out and apart:

Bad:

https://www.aulro.com/afvb/images/im...012/03/149.jpg

Good:

https://www.aulro.com/afvb/images/im...012/03/150.jpg

If you go to the thread on my 90 in my signature there is a step by step on how I rebuilt my transfer case. starts about post 341 and drifts on for a while!

Thanks for pics and info.

The link below will take you direct to post #341:
http://www.aulro.com/afvb/gclro-memb...ml#post1590779

The ashcroft cross pin looks very chunky compared with the standard item.

http://www.ashcroft-transmissions.co...&productId=138

Quote:

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Originally Posted by Psimpson7

They are not that hard to do.

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... nah easy as pie... :BigCry:
Think I will have to leave this one to the professionals. Hope Im not gonna be too much in the hole after this repair.
Also; sorry if its obvious/already been answered... will the loss of shims in the centre diff result in pretty bad backlash because Im still trying to figure that out to. :(

Pete,

Just wondering if you replaced the diff gears (or any others for that matter) when you did the o/h?

Trevor,

I believe the worn/destroyed shims do result in bad backlash. Mine had silver and brass glitter in the oil when I last did a change about 5-6K km ago. I really need to drop the oil again and see what's going on. It seems to have developed a bit of a whine when making a turn from a standing start and it clunks noticeably when lifting off the throttle.

Mine is a pretty much a daily driver so I'm trying to work out how to do a rebuild with minimal down time. I'm tempted to look for a transfer box from a MY02 D2 without the diff lock internals to rebuild then swap the front housing with diff lock mechanism when I pull the old box. Is it that simple of is there something I'm missing?

cheers
Paul

Hi Paul,

In the transfer case, I changed every single bearing and seal, the heavy duty cross pin for the centre diff, all the shims etc etc.

All the gears etc were like new and didnt need replacing. After taking advice I reused the centre diff housing with new shims.

Also interestingly, the kit is supplied with a crush tube for setting the preload on the intermediate gear. Even with my longest knuckle bar I couldnt get it to collapse atall. I ended up reusing the spacer I took out which was a precision ground much heavier wall tube than the replacement spacer. Slightly odd, I wondered if LR changed something later on, in the same way they did with the specific wheel bearing spacers they have now.

This worked fine and the preload is ok now.

Rgds
Pete

Thanks Paul,That's the best news I've heard all week. Finally something that is consistent with the backlash and those silver glitter parts and brass pieces in my t case. Thanks heaps for the explanation.


Pete,
Is it possible to give me a basic run down of parts needed to replace the centre diff? Is it just shims, upgrade to the hd cross pin and perhaps the planetary gears (I think that's what you called them, the ones you reused). Would i be expected to need much more than that for the centre diff. I want to get the guy who did my rear diff to do it but I'd like to supply at least the cross pin do I know it's a good quality. Thanks heaps for all your help guys. The good news, (relative to other outcomes), is quite welcome.


One more quick one, are the shims the only thing in the t case or centre diff that would create a bad backlash? If I can narrow done the possible causes then I'll be able to know what to expect cost wise. Also, I believe the HD pin is unique but what about the shims?
Sorry for all the questions guys.