Thread: Discovery 4 Transfer Case Slop / Thud on Engagement

Originally Posted by eddielines

Something just doesn't feel right.

That alone is a good enough reason to keep investigating.

Thanks Guys

Yep, got car off wheels last night.
Compared play and feeling of take up if slack in each inner cv. Nothing more than I feel would be expexted in rear. Front let a little bit although very minimal. Front right not massive like I see in videos but some obvious play.

Plan of attack is replace front right and if that helps but does solve it, then front left and if not fully solved have a good look at front prop.

I saw the rebuild kits for inner bit due to time will just replace I think.

@discojeffster I am still under warranty for trans rebuild if I think it's that I will be going back to them.

Just providing update for anyone that may be having the same issue.

Took it into Indy. He thinks it is the Transfer Case internal. He is going to change to OEM oil and if that doesn't help the recommendation is to replace with low KM 2nd hand that's had an easier life .

Royal purple sunchronax transfer case oil is as good as the oem snake oil. I ran it in my D4 SDV6SE transfer case for 60k km without issue. Slop is from mechanical wear, typically the splines. Try removing them and applying a liberal amount of grease. If intermal, i.e stretched chain in thr transfer case, then no amount of oil can fix that.

To close this out, mechanic is sure its the transfer box (chain), but its not that bad compared to a lot that people are doing nothing about. So I've decide to live with it for now, its not that bad, I barely get it with feathering accelerator, just working on that with my better half.

If it gets any worse I'll have them pull the Transfer case off and check splines and consider a low km replacement.

I'd also like to thank those that replied to my questions and contribute to this forum in general.

While I've never been into cars or mechanically inclined historically I'd consider myself reasonably competent and doing more and more since I bought the car 5 years ago. It wouldn't be possible with out this forum and its contributors and the Disco3 site in the UK.

Now if only I had somewhere I could put a lift !

Was checking out suspension and drive line as part of latest service. Bushes in front upper control arm on Drivers side are shot. Not sure why I couldn't see this when looking back then. Will loop back to confirm when replaced next week.

Oh, and I have a little grease on seam of front prop shaft and can find a minimal amount of play in it so that will be replaced now also. Has anyone replaced prop shaft with anything other than genuine of GKN and been happy with it, anything I've read said GKN new or low milage genuine second had ?

I’ve been chasing a thunk in front also and recently did tie rods. Next is upper arms have new bushes ready to go.

Interesting on LR Time yesterday same issue same diagnosis after doing tie rods.

Shane donated me some old upper arms from his D3 and the bushes were totally wrecked in those so 250,000km seems the limit.