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so an update: have managed to remove the double cap (top hat) from the end of the transfer case. It looked very clean inside. All three rods are able to moved - definately not sticking and well lubricated. The red lever happily moves the red nearest the drivers side backwards and forwards. The middle rod does not move when the yellow lever is depressed, so it is not lining up to drop the pin in the hole. ( red arrow) however the middle rod with the hole in, only moves when the red lever is pushed back into its start position ( i guess the normal way of taking out of 4wdh?)
I lifted the front wheels and engaged the free wheel hubs - neither 4wdh or low seems to be gaging as the wheels can still be turned when either high or low range is selected.
Does this indicate a spring is broken inside the transfer case? I'm guessing that will require a strip down and rebuild of the transfer case?
Attachment 193407
Any thoughts most welcome!
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On further investigation, I’m now wondering if it’s not the transfer case at all…. When engaging low or high range 4wd, the front drive shaft is being engaged and is spinning! When disengaged, it obviously stops spinning! So therefore, is the issue further down the driveline and maybe a problem with the front differential or axle components?
I’ve noticed a knocking when in reverse that sounds like it’s coming from forward of the gearbox/transfer case…. No knocking when in forward. Also both front wheels are very difficult (stiff) to revolve when on axle stands in neutral and free wheeling hubs engaged or disengaged.
a friend of mine is wondering if there is damage to the bevel pinion???…… I’m at a loss where to go next!!
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After watching this video on a snapped front right axle, could this be the problem?…… I’m now officially down a rabbit hole!!!
https://youtu.be/2qQsutC06cQ
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From what you say, I am suspecting a broken component in the front axle. Most likely is one of the free wheel hubs (could be stuck in the free position rather than broken) - I do not recognise the type of hub.
A couple of steps you could take -
1) Drain the front diff and check what you drain for any unexpected bits of metal. A broken front diff is unusual, but can happen.
2) remove both free wheel hubs and check whether the stub axle is turning (note that because of the differential, it only takes a break anywhere on either side to stop both wheels from driving.)
3) Next step would be to remove each front hub assembly and withdraw the half axle and universal. This will be needed to remove the diff.
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So a colleague and I have spent the day pulling both front axle hubs apart, expecting to find a broken half shaft or something! To my horror, everything looked fine! On taking the free wheel hubs apart, it seems I have found the problem!!I found grommets thread of the rebuilt selectro free wheeling hubs! Very informative, as I have exactly the same on my 75 109.
the problem I have is that on the left hand side, the teeth have worn away on the inside of the ring that gets pushed into engage. Looked everywhere for a replacement, but so far no joy. Any suggestions on where to look?
I guess some people have to learn stuff the hard way!
cheers
chris
sames1972
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What brand of free wheeling hubs?
whitehillbilly
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What is your planed usage for the car?
You could just put standard drive flanges back on it.
Tony
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I might have what you need.
If I can remember which box I put parts in 2 days ago [bighmmm]
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Sounds a bit like my shed!
