Thread: Excessive backlash 2004 D2 v8 r380

Originally Posted by strangy

So 6 months back it was good.
The only change is unevenly worn tyres though same size...It wont be this if:
Same size equals width and profile. eg 235/70 all round vs 235/75 mixed with 235/65 etc.

Which leaves the rear diff....
If all above is correct- thats the go to point.
Disconnecting shafts and engaging CDL will always exacebate the Transfer case backlash as the CDL drive collar has significant spline to drive collar clearance, allowing the centre diff to pick up that slack in the CDL engagement and enhancing any back lash whilever a shaft is removed.

With the shafts off compare front diff backlash to rear.
As a guide only for further investigation - on a D2, normal is anything less than 10mm on the drive flange circumference.

So based on your info , my money is in the rear setup.

Okay so last night i put the vehicle into transfer case neutral and unlocked diff. That way i could fully see the backlash from the front and rear diff. The front and rear diff backlash looking at the drive flanges was the same. I am now turning my attention to the Transfer case. I will be dropping the inspection cover off today.

So i will get to the bottom of this backlash, but i have not uncovered it yet.

I pulled the TC inspection cover off a week ago, i ran my finger along the whole bottom of the "sump" area. I could only find 1 piece of gold coloured material. this one piece was circular, it was 0.5mm thick and 2.5mm in diameter. it looked like the transfer case had not been opened throughout its life so i figure that that brass is the only piece that has come dislodged from the bearings, although with the factor of previous oil flushes i may be incorrect.

sigh.

I am now stumped. i might get on my local discovery page and ask to inspect the play on all drive components on someone else's car that has not got a backlash issue.

The shims in the CDL wear,its seen as gold dust in the oil.
Ashcroft do a strong limited slip conversion for the CDL.
My old D2 had bad backlash,I had the clutch/transfercase done,the shims in the CDL were shot.
After it was perfect.
Andrew

Yes, those shims were completely dissintegarated in mine, IMO the best thing to do is to use the master rebuild kit if you take the TB apart anyway, the shims are part of the kit

Originally Posted by sierrafery

Yes, those shims were completely dissintegarated in mine, IMO the best thing to do is to use the master rebuild kit if you take the TB apart anyway, the shims are part of the kit

It looks like this will be the way to go. Just to make absolute sure it is not the rear or front diff, i compared the back lash of the front and rear diff (at the flange), to a low mileage d2a that a friend owns. i measured the slop accurately making marks along the circumference. They were nearly identical for both vehicles. I can therefore rule out front and rear diffs for the meantime.

I am replacing the clutch in a few days. I will be dropping the gearbox and transfer out while doing this, during this time i will pull the center diff out and inspect it. Even though i couldnt find anything while i had the transfer inspection plate off, the gold dust may have been flushed out during the multiple flushes i have done to the vehicle since i have had it.