Thread: D2a Transfer Case Woes

I get the feeling that Im looking at the idler gear shaft...

Not supposed to look like that tho Especially if they havent taken it apart....

look on the back of the Tcase (obscured by the handbrake) and you should be able to see the other sidee of it. If its not correctly secured Id be getting all upset over the phone with lots of "what were you clowns thinking?"

IF they serviced it and it was low on oil (doesnt count if theres a leak) they are responsable for it. bet they claim it all leaked out the front shaft seal.

mate thats knackered!!!
that is a gear shaft, ONE THAT SHOULDNT TURN IN THE CASE!!!!
i cant give you a better idea of what shaft exactly it is, moved house cant find rave cd.
i reckon the inside would look like.....well..... its probably not what it should!

in short, they serviced it they can sort you a replacement.

cheers phil

And further to the exclamations of the above - a translation of sorts, or a guess by me of what at least has happened.

Firstly, the center diff: If it was stuck in lock on the straight bitumen, it may have survived. The tyres are more prone to wear in this situation apparently.

(But still requires a look-see at the center diff).

As for low/no oil - are the output seals intact? Figuring out how the oil got out is the key. It is more likely that loss of oil has caused both the diff to lock up and the shaft problem. You can run a TC with dud intermediate seals and still have a decent amount of oil in the TC - but if the output seals go, then it's all over.

As to the intermediate gear shaft turning in it's housing - it may be that the bearings supporting the intermediate gears have got hot, seized, chewed the locking plate and allowed the aluminum housing to act as a sleeve bearing.

Can't go past the phrase 'take it off and have somebody who knows what they are doing rebuild it'

So I guess my question is, will any LT230 fit? I happen to have a spare out of an earlier model rangie.

What are the differences and can it be made work?

They knew about the leak from the rear seal, I asked them to fix it but they said it will be fine.

In the absence of more qualified information: Any LT230 should bolt on - but I suspect that the output flanges have changed with the D2. Find two spare D2 output flanges and they should (Again, this is a partially qualified guess) get you back on the road.

Hi,

ideally you want another early D2 one, preferably a type 41D as this will have diff lock,

you can modify a 200 or 300 TDi type 28D or 36D but you will need to fit your :

1) front drive flange
2) hi/lo casting, as the lever is different
3) rear transfer case housing, or you can just leave the speedo drive gear in and put the cable clamp fork back on to hold it in and if it doesn't leak which it shouldn't, just leave this alone,

Dave

Originally Posted by Maggot4x4

They knew about the leak from the rear seal, I asked them to fix it but they said it will be fine.

they were wrong, thats just bloody poor workmanship (and lazy)

Id go em.