6hp26 transmission / transfer box failure

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Originally Posted by rar110

5L40 tranny owners you are not alone.

OK, as some might have noticed, I had a total failure with my tdv8 tranny nearly 4 weeks ago. It went wiz and all drive stopped.

The advice is that the output shaft on the 6 speed zf is stripped at the transfer box end, and the receiving drive gear on the transfer box is stripped or near so.

This has occurred on a 08MY L322 with 240,000km, so Im not shocked about something like this happening. It was a bargain tdv8 L322 and my plan from the beginning was to put a bit of money aside each year for a catastrophic failure of some kind. Based on the experience of others I was hoping it would last at least another 50,000km. However, it has happened earlier than I had planned for.

I am looking at a bill of $7-8000. So any advice would be appreciated.

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Sorry to hear Pete.......hope it works out ok?

Ta Grant I might actually be lucky in finding a solution.

The tranny would let go some stage with the km. The turbos/egrs are another risk area for me to plan for. I got it cheap with these risks in mind. Unfortunately it happened earlier than anticipated. Better it occurred near Brisbane than near Karumba. It's still the best vehicle I've driven in. No regrets at this stage.

Will do an update in a month or two.

How's the box going Rar110

I had a look at the transfer box out. The box where it joins the transmission was coated with fine rust powder, which are the remains of the spline.

Apparently the earlier tdv8 output shafts splines weren't coated with grease and so rust/wear. Given its only attached with about 8 bolts, I'd be slipping it off at 100,000km to at least check and re-coat.

I have a used box lined up. Hopefully it all works. Anyone have the ZF spec numbers for the pre facelift L322 tdv8? The box I bought is from an early (2009) facelift model with ZF spec 1068 020 075.

What years didn't have the grease?
Is the transmission still ok?

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Originally Posted by Blade74

What years didn't have the grease? Is the transmission still ok?

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I don't know. Mine certainly didn't have any or sufficient. However it does have 240,000 km. The output shaft needs replacing, which means emptying the box.

It was going great until the failure.

As it seems so easy to do I think it should be recoated as part of a transmission service.

I took a pic of the back of the transmission this morning.

Attachment 96245

Also the ZF specification numbers on the boxes are the same.

The FFRR is back on the road with a new tranny and transfer box. It feels more responsive now. It's fantastic driving it again.

Good to hear.

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Originally Posted by rar110

The FFRR is back on the road with a new tranny and transfer box. It feels more responsive now. It's fantastic driving it again.

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Great news Pete

Cheers Steve