LT230T Transfer Case - Intermediate Gears loose

**chosen** · 31st July 2007, 05:59 PM

Hi guys,

Pulled the inspection plate off my TC today and noted about 5mm play (side to side) and perhaps 1-2mm play up/down with the intermediate gears

Well it has turned out that this play in probably the source of all the horrid whine that I have been experiencing of late.

My question is this... can I get rid of the play solely by tightening up the stake nut?

If not (which I expect) would you say it is worth me pulling the whole TC out and replacing the bearings on the intermediate shaft OR purchasing a low Km Second Hand TC for $1,200 (6 month warranty)?

To replace these bearings will I need to remove everything else and are there any weird tools required to do so?

Thanks a lot all of you,

Chosen

(you may remember other threads I started about gearbox whine, um sorry for starting a thread before I had a better understanding of the whole picture - it is my 1st Land Rover)[/SIZE]

**jimbo110** · 31st July 2007, 06:08 PM

Really you will need a new transfer case. the gears will have worn out of alignment and even with new bearings and the gears lined up right again they will whine/howl

from the odd wear pattern

**chosen** · 31st July 2007, 06:20 PM

Originally Posted by jimbo110

Really you will need a new transfer case. the gears will have worn out of alignment and even with new bearings and the gears lined up right again they will whine/howl

from the odd wear pattern

Hey jimbo110, so if they've worn out of alignment would I be able to tell by looking at them, or is it a case of "they have worn, that is the way it is"?

**jimbo110** · 31st July 2007, 06:55 PM

It's hard to tell by looking at them, even replacing a gear with a new one can cause gear whine. 5mm side to side play is huge on tapered rollers, so something big must have happend to them. on the early transfer boxes you can adjust free play/pre load by tightening the nut, on the later ones the spacer between the bearings is solid and wont collapse so cant be adjusted. The only way to tell is to pull it apart and see if maybe it has a collapseable spacer that has done just that and let the bearings go loose. but you could fix that and still have a noisy box due to odd wear of the teeth. only guaranteed fix is another one.

jddisco200tdi · 1st August 2007, 09:30 AM

I've had the problem you are experiencing.
You will have to replace all the gearsets to get rid of the whine.
You can tighten the nut up to get the right bearing preload and align the gears but it will stay noisy.

On the gearset I had removed you couldn't visibly see wear but they made more noise than the engine.

Could be an opportunity to put in defender 1.4 gears and MD crawler gear for big tyres.

**chosen** · 1st August 2007, 09:53 AM

Originally Posted by jddisco200tdi

I've had the problem you are experiencing.
You will have to replace all the gearsets to get rid of the whine.
You can tighten the nut up to get the right bearing preload and align the gears but it will stay noisy.

On the gearset I had removed you couldn't visibly see wear but they made more noise than the engine.

Could be an opportunity to put in defender 1.4 gears and MD crawler gear for big tyres.

Well there you go... new gear sets would be more expensive than that $1,200 box (especially with new bearings) that about says it all then :-(

I like where you're going with regard to the defender 1.4 gears (or MD crawler gears) for big tyres!!!

**chosen** · 1st August 2007, 10:04 PM

Okie Doke, Today I adjusted the Bearing Preload (intermediate gears) in the TC, it has taken up the slack in the Case. The noise is still there, may be just warn gears but I suspect it is the bearings also. I'll drive it around until/if it starts getting noisier and then pull the whole thing out and do the blasted bearings or replace it then...

Cheers all

**Bush65** · 2nd August 2007, 08:55 PM

Noise (whine) from gears comes from minute errors in the tooth profile that lead to loss of conjugate action.

The mating teeth only have rolling contact at the pitch line. Sliding contact increases toward the root and tip of mating teeth. The contact pressure (and stress) changes depending where the teeth are contacting as the move into/out of mesh.

When the bearings wear, the mating gears move apart and operate on incorrect centre distance. Even worse is the different separating forces at the other gear set on the shaft cause angular misalignment of the gear teeth and they are forced to have higher loads on one end (the load is not distributed uniformly along the width of the tooth).

All of the above means that wear of the tooth profile is not uniform, resulting in tooth profile error.

Edit: it is also important to change the oil in the gearbox and t/case. Oils deteriorate, and the R380 in particular suffers from overheating. Wear particles in the oil end up in the gear mesh and bearings, which lead to accelerated wear.

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