urgent help needed- RR broken up the bush.

**POD** · 4th April 2011, 07:40 PM

Headed up into the high country today planning a few days solo deer hunting. Got a little way in towards my campsite when I lost all drive. A lot of walking and 3 different lifts later, I'm at home and the Rangie is still up the bush.
Vehicle is 1990 RR with auto and viscous transfer.
I strongly suspect that the splines in the output of the transfer have stripped, but would appreciate some confirmation that that is (or isn't) the most likely problem, before I drive the 3 hours back up there to sort it out.

Symptoms are:
No drive, forward or reverse. Neither of the propshafts are turning (so not F or R diff).
Grinding noise, seemingly from within the transfer case. Grinding noise is fast in high range and slow in low range. Grinds in both reverse and drive.
This happened when I was going down a steep gradient in low range and had to reverse up the hill a short way to avoid a fallen tree. As I selected reverse and went to start backwards, it let go.
One more thing, and this is the one thing that makes me worry that my diagnosis may be off: the high/low lever has become very sloppy. feels like it is selecting, but with absolutely no resistance.

I'm trying to get as much info as i can to figure the best way to attack this. My options are:

1; Go back up there and tow the thing all the way home. Difficult, but possible. I have a rigid tow hitch, and the engine runs so brakes are functional. Hell of a long way to tow though.

2; Take the LT230 out of my discovery (planning on wrecking it soon anyway), and go up and swap the transfer case in the bush.

3; I have another Viscous transfer, in bits, on the bench in my shed. I'm heading out there now to figure out whether I may be able to just swap out the centre diff. Need advice here as well; the transfer case in the shed has a seized viscous coupling (reason it's in the shed). if the splines have stripped, do I need to swap the viscous, or just the centre diff? Can the centre diff be pulled out the front in the same way that the viscous is pulled out the rear of the case?

I'm heading out to the shed now to look at the transfer and see what I can nut out, will look for help here when I get back inside- thanks in anticipation.
Pete

**PhilipA** · 4th April 2011, 07:52 PM

Sounds like you are on the money, but the floppy lever sounds funny.

AFAIR the viscous is at the front. I am pretty sure you have to split the main case for the centre diff. Why not swap the cases completely and swap over the viscous coupling which is in its own extension.
I fear you have to take the case off anyway.

Regards Philip A

**tuffrangie** · 4th April 2011, 07:53 PM

I would suggest tow it to the nearest main road and join RACV Total Care, you get a free tow to the mechanic of your choice/your house etc.. up to 100km i think.

Sorry I can't be of more mechanical help. Not a busted output shaft on the auto?

Rob

**POD** · 4th April 2011, 08:16 PM

Originally Posted by PhilipA

Sounds like you are on the money, but the floppy lever sounds funny.

AFAIR the viscous is at the front. I am pretty sure you have to split the main case for the centre diff. Why not swap the cases completely and swap over the viscous coupling which is in its own extension.
I fear you have to take the case off anyway.

Regards Philip A

Yes just refreshed my memory and the centre diff- where the suspect splines are- is right in the middle of the big sprocket, so case has to come out.

The floppy selector lever has me tossed- I'm wondering whether it is just not fully engaging, but if so, the trouble is probably inside the case anyway so no help. I would have liked to have had time to investigate further but didn't want to walk the 30 k's into Licola in the dark.

**POD** · 4th April 2011, 08:22 PM

Originally Posted by tuffrangie

I would suggest tow it to the nearest main road and join RACV Total Care, you get a free tow to the mechanic of your choice/your house etc.. up to 100km i think.

Sorry I can't be of more mechanical help. Not a busted output shaft on the auto?

Rob

Pretty sure it's on the output side of the transfer, as the noise is different between high and low range.
Unfortunately it's well over the hundred k's from home, and by the time I get up there and tow it out to the main road, might as well tow it home I think. Looking like the best option at this stage.

mike 90 RR · 4th April 2011, 08:38 PM

Originally Posted by POD

Pretty sure it's on the output side of the transfer, as the noise is different between high and low range.
Unfortunately it's well over the hundred k's from home, and by the time I get up there and tow it out to the main road, might as well tow it home I think. Looking like the best option at this stage.

From what your describing, I'm 95% sure your on the money

I have had the same symptoms and have done the repair ... Infact I put up some pics of the shagged spline for PhillipA ... I think it's titled "For PhillipA" ... I'll have a hunt for it

In the mean time ... The method to replace is pretty simple
Put the Transfer case in neutral
Drain the oil in trans case
Take the rear prop shaft off
Remove the speedo cable
Remove the Drum hand brake
Remove the rear output housing
The housing and shaft will all come out as 1 unit

If you have another (spare) housing with shaft ... Then just install it

Reverse the procedure to install other parts
Fill with tranny fluid Dexron 111

Drive home

mike 90 RR · 4th April 2011, 08:41 PM

Originally Posted by mike 90 RR

I have had the same symptoms and have done the repair ... Infact I put up some pics of the shagged spline for PhillipA ... I think it's titled "For PhillipA" ... I'll have a hunt for it

Remember to take a oil hand pump ...or those little 500mm oil bottles

Do you want me to find those pictures??

mike 90 RR · 4th April 2011, 08:45 PM

Originally Posted by mike 90 RR

Do you want me to find those pictures??

Found them ....

Borg Warner Achilles heal?

Oh ... and take a bottle of "Hollimar3" gasket goo

**superquag** · 4th April 2011, 09:21 PM

My extreme sympathies to you POD....

Thanks guys, - reading through and following the link to the viscous/LT 230 makes me suspect my viscous as being on the way out... at 155,000km.
- Symptoms are: when turning sharply the engine is severely loaded and on sand you can hear and feel tiny bunny-hops, like axle wind-up in a conventional 4WD.
Front tyres are badly feathered, especially when considering that they've been well inflated... - 40 psi at the moment to see if this alters the wear pattern...

James in Gosnells.

Planning on taking my Pajero and car trailer to the bush... using the RR to impress everyone, then re-load it and trailer it back home.
That way I *know* I'll get there and back...and through the ruff stuff in style.

**POD** · 4th April 2011, 09:39 PM

Originally Posted by mike 90 RR

From what your describing, I'm 95% sure your on the money

I have had the same symptoms and have done the repair ... Infact I put up some pics of the shagged spline for PhillipA ... I think it's titled "For PhillipA" ... I'll have a hunt for it

In the mean time ... The method to replace is pretty simple
Put the Transfer case in neutral
Drain the oil in trans case
Take the rear prop shaft off
Remove the speedo cable
Remove the Drum hand brake
Remove the rear output housing
The housing and shaft will all come out as 1 unit

If you have another (spare) housing with shaft ... Then just install it

Reverse the procedure to install other parts
Fill with tranny fluid Dexron 111

Drive home

I've just come in from the shed again sorting out tools and bits, my plan was to take the transfer case with me, swap them over and swap the viscous, but I would need to dismantle and assemble up there as there are a couple of bolts missing on the shift mechanism inside the one I have spare.

Have just seen Mike's post which is VERY encouraging, as it appears that the female splines might be still okay- this is fantastic- if i can just swap the rear output housing I'll be ECSTATIC. Have a mate coming at 7am to head back up there, it is bad enough that he has to take me there in his Toyota to rescue the Rangie, but my life may still be worth living if I can avoid having him tow me home!

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