Thread: LT95A. Intermediate Shaft Bolt Issue

That bolt holds the main transfer gears together and needs to be replaced
It is not difficult and can be done without removing the gearbox
Open the access panel ( after draining the oil) and you will see how it works. The bolt is available.
Do not drive the vehicle with the damaged bolt in place. You could destroy the transfer case and that will cost many thousands to repair.

Note the last few words in this from the KLR Auto website:
LT95A Intermediate Shaft Bolt, Perentie - KLR Automotive

203mm bolt for the intermediate cluster in the transfer case of the LT95A gearbox (usually found in Perenties). Only suits the taper bearing type. This is the plain shaft bolt. If you have the stepped shaft (FTC1058) it is highly recommended to replace it with this one before the bolt breaks.

Originally Posted by I Love My Landy!

Good afternoon all,

I am posting this on behalf of my Dad who owns a 110 Perentie. Any advice would be much appreciated 🙂

LT95A perentie transfer box jumps out of reverse under load even under light loads. Sometimes jumps out of forward gears after reversing.

In one of Bearman's threads he said to make sure the intermediate shaft bolt was tightened to the right torque. l checked it and found it finger tight. When i tried to tighten it just turned and then the bolt moved out away from the casing by about 3 mm. It feels like the bolt has snapped around the threaded area.

I've done about 60,000 km on it without noticing any problems or noises..gears shift ok..high and low range selector is sometimes hard to click into gear but once in seems to stay in. What is the purpose of the bolt..is it just to keep the shaft from sliding out or for preload purpose? Will it damage the t.case if i keep driving? I have made a locking tab to stop the bolt from sliding back . I suspect that the bolt may have overtightened and snapped at some stage. Does the thread go into the alloy casing?

Many thanks 🙂

Edward

Edward, that bolt holds the gears together on the intermediate shaft and will be the cause of it jumping out of gear. Most likely it is the older stepped type bolt which is prone to breaking. Don't drive it until you have fixed it. Whether it's an easy or hard fix depends on where the bolt has snapped. If it is in the thread area you will most likely be able to remove the shaft with the gears and get the plug out that the remains of the bolt are screwed into. However if it has snapped along it's length you are going to have some fun getting the shaft out intact. Drain the oil and take the handbrake assembly and transfer sump off. Then you can pull the bolt right out and see where it has broken. If it is right at the end where the tread is you should be able to get the complete intermediate shaft out with all the gears on it from underneath (it may even fall out when you withdraw the bolt) However if the bolt is snapped further along it's length you are going to have to try to turn and unscrew the broken bit with a LH drill bit or similar. If all fails you will have to run an oxy torch through the smallest gear and shaft to remove it.

My Dad asked me to thank you all for your replies. It is much appreciated!

He is going to pull it down tomorrow. I'll let you all know how he goes.

Edward

Good morning all,

An update from my Dad:

Went to take the intermediate shaft out - withdrew the bolt and found it broken at the third step-down (see photos). Went to slide intermediate shaft out but it only slides out 3 mm and comes to a stop with a solid clunk sound. Tried levering it out with screwdriver while lifting the gears but it won't come out.

What is stopping it from coming out? What should i do next?

Many thanks,

Edward

Good afternoon all,

Another update from my Dad:

I came up with an idea of using a rattle gun to remove the shaft. The bolt had sheared off with a piece sticking out and mated with the other broken bit. With some pressure on the rattle gun it unscrewed the broken bit and the whole lot fell on the ground (oh what a feeling!).

I hope that if anyone has a broken bolt it breaks this way - at least there is an alternate way to get the bolt out.

Thanks for the very helpful posts. I guess i was lucky I didn't have to resort to the other methods.

Edward

Edward, you are very lucky, normally they shear in a straight line. Well done. Make sure you buy the new type bolt AYG3388. They are straight with no shoulders.

Thanks Bearman. Yep, kinda makes up for all those other times where we have been very UNlucky!

Thanks for the tip regarding the new bolt. My Dad has spoken to the guys at KLR about the new bolt. They are currently out of stock at the moment as they have apparently replaced 3 broken ones in the last week alone!

Edward