Thread: Suspect trransfer case

Yet again I seek the experience of the forum sages. This time it is a drone heard inside my 2002 TD5 auto when I get over 50 KPH. It sounds a bit like a 4wd tyre drone but it is not tyres because the noise is still there when I jack up 1 front and 1 rear wheel and “drive” the car in situ. Plus when I jack up just 1 rear, or just one front wheel, and drive the car in situ there is a nasty bearing like screech when I back off from high speed. It is not the front prop shaft because that is brand new. I dropped the transfer box oil and it was up to the mark and fairly clean but there was fine black pastey, sludge and swarf on the magnet plug. The swarf was bigger than iron filings and more numerous that I expected. Looking at Rave, I suspect centre diff carrier bearings. Before I remove the whole tansfer box, any suggestions? Thanks

Just completed the tfr box rebuild on son 3's D1. Get a complete rebuild kit (including all bearings), but because you have D2, when you set the intermediate shaft up, you'll need to get selective spacer if you can.

I can't remember if the kit has centre diff thrust washers. You may need cross shafts, and maybe even side gears, but you won't know until you get it to bits and check everything. You'll need access to dial indicator to measure backlash for bearing preloads.

It's not particularly difficult, just painstaking. If you take your time, it's a rewarding DIY.

Check the spud shaft on the gearbox for excessive backlash in the transfer gear, and the transfer gear for excessive spline wear.

The overhaul manual in RAVE2 (or 1) is easily followed.

Cheers

Pete