Thread: handbrake slipping on D2

Hi Feraldisco,

When do you use a handbrake on a firetrail?

Originally Posted by feraldisco

Hi - I managed to overfill the transfer case on my D2, but fortunately realised this before I'd driven the vehicle, so removed excess immediately. Ever since then, my handbrake isn't doing it's job. My LR mechanic reckons the seal in the transfer case is very good and that overfilling shouldn't be a problem unless the vehicle is driven with excess fluid. However, my overfilling must have caused the problem, and even with the handbrake adjusted, it won't hold on steep hills which makes me nervous about firetrail work. Please tell me that this problem can be solved without major removal of components/cleaning/resealing etc!

My fender, being brittish, leaks oil and it runs down the handbrake cable into the drum. Did you spill any in this area. I find that after a while it works again, I haven't done anything to fix it and it's been fine for ages now. If you need to clean it it shouldn'e be hard to get the drum off.

Originally Posted by Bushwanderer

Hi Feraldisco,

When do you use a handbrake on a firetrail?

Generally you wouldn't - i.e. you'd wait for the person in front to complete a gnarly section and then do it all in one hit, hoping you don't have to stop part way for any reason. However, during 4WD training, stall starts etc are a requirement, and this type of thing will be a bit difficult without a handbrake. My house is also on a steep slope, so the handbrake is pretty essential for parking trailers at the top of the hill etc.

I didn't spill any around the drum area itself, so I can only assume that some has made its way past the transfer case seal. Either way, sounds like it's easy enough to remove the drum to clean it up.

Originally Posted by feraldisco

Hi - I managed to overfill the transfer case on my D2, but fortunately realised this before I'd driven the vehicle, so removed excess immediately. Ever since then, my handbrake isn't doing it's job. My LR mechanic reckons the seal in the transfer case is very good and that overfilling shouldn't be a problem unless the vehicle is driven with excess fluid. However, my overfilling must have caused the problem, and even with the handbrake adjusted, it won't hold on steep hills which makes me nervous about firetrail work. Please tell me that this problem can be solved without major removal of components/cleaning/resealing etc!

Just wondering how you overfilled the transfer case?

The RAVE CD shows;
MAINTENANCE
PROCEDURES 10-25
Transfer box
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Check/top-up oil level
1. Release fixings, remove rear underbelly panel.
2. Clean area around oil filler/level plug.
3. Remove oil filler/level plug.
4. Check that oil level is to bottom of filler/level
plug hole.
5. Top-up level (if required) with recommended oil
to bottom of oil filler/level plug hole.
+CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
6. Remove all traces of sealant from threads of oil
filler/level plug.
7. Apply Loctite 290 to threads of oil filler/level
plug.
8. Fit transfer box filler/level plug and tighten to 25
Nm (18 lbf.ft).
9. Remove all traces of oil from main casing.
10. Fit rear underbelly panel (if fitted), secure
fixings.
Replace oil
1. Release fixings, remove rear underbelly panel.
2. Place a suitable container beneath transfer box
drain plug.
3. Clean area around oil filler/level and drain
plugs.
4. Remove oil filler/level plug.
5. Remove oil drain plug.
6. Allow oil to drain.
7. Apply Loctite 290 to threads of oil drain plug.
8. Fit transfer box drain plug and tighten to 30
Nm (22 lbf.ft).
9. Fill transfer box with recommended oil to
bottom of oil filler/level plug hole.
+CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
10. Remove all traces of sealant from threads of oil
filler/level plug.
11. Apply Loctite 290 to threads of oil filler/level
plug.
12. Fit transfer box filler/level plug and tighten to 25
Nm (18 lbf.ft).
13. Remove all traces of oil from transfer box.
14. Fit rear underbelly panel (if fitted), secure
fixings.

I thought the oil went in via the oil filler/level plug.

I am willing to learn new information.