LT95 jumping out low range (at the worst possible moments)

**mark2** · 7th April 2009, 07:10 PM

My LT95 has been giving me a few scares lately, jumping out of low range on steep descents. It doesnt always do it and at times I've wondered if I've actually put the lever down far enough but its happened enough now for me to start looking a bit further.....

What are the likely suspects?

**Blknight.aus** · 7th April 2009, 07:24 PM

worn teeth on the engaging dogs of low range, the rubber matting on the top of the box fouling the lever, and the linkage being damaged/fouled by debry.

**rovercare** · 7th April 2009, 08:10 PM

Or shims/needle rollers/worn shaft on the intermediate gearset

**Blknight.aus** · 7th April 2009, 09:13 PM

although that normally also results in high range doing the same thing...

**Bearman** · 7th April 2009, 09:24 PM

Could also be the adjustment on the selector forks. Might be worth checking this before dismantling. The way of doing this is to put the lever in neutral, Take the top plate of the transfer case above the intermediate shaft and make sure the front fork is in contact with input gear engaging member. There should be a clearance of 0.12 to 0.25mm (0.0005 to 0.010in) between the face of the rear fork and the rear engaging member of the input gear. If this adjustment is correct I would then look at the engaging lugs on the small (low range) gear. If there is wear there (indicated by chipped or tapered engaging lugs this could be the problem. If the adjustment is incorrect you can adjust it by loosening the pinch bolt on the selector and retightening when the correct adjustment is obtained.

**rovercare** · 8th April 2009, 06:30 PM

Originally Posted by Blknight.aus

although that normally also results in high range doing the same thing...

If its the shims, yes, it will eventually be both, but if the lay shaft case hardening has started to come away, or the needle roller set on the low range gearset has pooed itself, it may only be low

**mark2** · 9th April 2009, 07:10 PM

Originally Posted by rovercare

If its the shims, yes, it will eventually be both, but if the lay shaft case hardening has started to come away, or the needle roller set on the low range gearset has pooed itself, it may only be low

Its not noisy in low range however xfer oil has a fair amount of bronze in it...

**mark2** · 9th April 2009, 07:37 PM

Originally Posted by Bearman

Could also be the adjustment on the selector forks. Might be worth checking this before dismantling. The way of doing this is to put the lever in neutral, Take the top plate of the transfer case above the intermediate shaft and make sure the front fork is in contact with input gear engaging member. There should be a clearance of 0.12 to 0.25mm (0.0005 to 0.010in) between the face of the rear fork and the rear engaging member of the input gear. If this adjustment is correct I would then look at the engaging lugs on the small (low range) gear. If there is wear there (indicated by chipped or tapered engaging lugs this could be the problem. If the adjustment is incorrect you can adjust it by loosening the pinch bolt on the selector and retightening when the correct adjustment is obtained.

This top plate of the transfer case - is it accessable from underneath? Is it the only removable plate apart from the bottom plate?

**Bearman** · 9th April 2009, 07:37 PM

Originally Posted by mark2

Its not noisy in low range however xfer oil has a fair amount of bronze in it...

That will be from your intermediate shaft thrust washers. I would say a rebuild is required. Remove the intermediate shaft and inspect and replace any worn bits. At the least you will require new thrust washers,bearings and possibly the shaft. It will be the endfloat caused by the wear on the thrust washers that is causing it to jump out of gear.

**Bearman** · 9th April 2009, 07:47 PM

Originally Posted by mark2

This top plate of the transfer case - is it accessable from underneath? Is it the only removable plate apart from the bottom plate?

If its a Rangie I am not sure whether you have access to it from above, maybe some of the RR gurus on the forum can enlighten us on this - in a defender it is accessible when you remove the centre console and flat plate underneat it. Rest assured if the oil looks bronzey it will be the intermediate shaft thrust washers. The only other place it can come from is the centre diff thrust washers. So, with the problem you are having I would be pretty certain thats where the bronze is coming from. I would have to check but I am pretty certain that I may have a s/h set of those thrust washers here. I would have to check to ensure they are serviceable as they came out of a box that I recoed with a trb setup. I am pretty sure that the shaft/pin was u/s from hardcase lifting. Let me know if you want me to check them......Brian

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