Thread: High KMS - Transfer case...

Originally Posted by Jeffoir

IMG_1567.jpgIMG_1566.jpgDear AULROVIANS,

My D4, which does the expedition work, with 220,000 kms, was going rapid fire ?clunk, clunk, clunk? when accelerating around a corner, after stopping.

A transfer case recalibration did not fix it.

Pulled the transfer case out and the pictures tell the story. Lots of ?fretting corrosion? with just a trace of residual grease, on the bottom of the surround of the input drive on the transfer case.

I'm exploring options. I will update as we go along.

thank you and best wishes to all. Jeff.

This is the great unknown on mine if some got enough grease or none got enough grease. How did the removal go?

Problem is if the wear is severe on the female side not an easy fix.

Will watch with interest.

Hi Everyone,
further to post 111 above, here is an update:
1. Researched doing either a rebuild, buying a reconditioned case or buying low milage 2nd hand case.
2. when Indy hours are costed in (as I do not have the tools and experience to rebuild myself,) I chose the 2nd hand case. See photos.
3. the 2nd hand case has an O Ring. My old case DID NOT.
4. have ordered new O ring and the Molybond GA50 Assembly grease to fully lubricate and seal the spline area.
5. will be reinstalling next week.

Perth Disco at post 112 asked if case removal was difficult. Answer: Yes, it takes time because the top bolts are difficult to access.
Indy, who is an automatic transmission specialist, not a full-time LR mechanic, rigged up a number of extensions onto a socket to remove. Indy has since ordered a set of the short torque adaptor spanners, for reinstallation. These spanners are referenced further back in the Thread.

You Tube's LR Time has this covered the transfer case removal their video called WORKSHOP FAIL. Christian makes his own special tool naturally. He is a classic!

Another update next week.

best wishes, Jeff.

Originally Posted by Jeffoir

IMG_1567.jpgIMG_1566.jpgDear AULROVIANS,

My D4, which does the expedition work, with 220,000 kms, was going rapid fire ?clunk, clunk, clunk? when accelerating around a corner, after stopping.

A transfer case recalibration did not fix it.

Pulled the transfer case out and the pictures tell the story. Lots of ?fretting corrosion? with just a trace of residual grease, on the bottom of the surround of the input drive on the transfer case.

I'm exploring options. I will update as we go along.

thank you and best wishes to all. Jeff.

So are you doing anything about the gearbox end of the joint Jeff? Or just replacing the TC case?

My MY14 D4 is at 370,000km. This thread is freaking me out!

Originally Posted by cjc_td5

So are you doing anything about the gearbox end of the joint Jeff? Or just replacing the TC case?

My MY14 D4 is at 370,000km. This thread is freaking me out!

Hi Chris,

On the Gearbox end, after a thorough clean, the splines were deemed serviceable.
My transmission Indy, who is doing the job, said that replacing the Gearbox shaft, (the Male Part) would be towards the final part of a transmission dismantle. This would be quite expensive.

It is his opinion that:
1. Given the very good condition of the splines on this 2nd hand replacement transfer case i have just purchased (see photo above,) and
2. The thorough clean and Moly lube of the gearbox splines which is about to be done, and
3. Installing an O-Ring.
that the job should be reliable for many, many more kms.

We can correspond more next week, after the job is complete.

However, with your D4 at 370,000kms, it is almost certainly due a good lubrication of the splines. To be economical with time, getting the T Case separated from the Transmission, is a specialist job. You are in WA. I suggest that you speak with Dazza at Aztec. He is right across this issue.

Best, Jeff

My local country general purpose mechanic removed the TC from my MY12 L322 at 150K kms to re-lubricate the splines then reftted the TC. There's nothing special about removing the TC although LR recommend fitting new tailshaft flange bolts.
I supplied a new oil seal for the TC input shaft.