UK replacement LT95A options failed synchro

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Originally Posted by p38arover

Doesn't oil migrate from the gearbox to the transfer case?

KLR Automotive sell a kit which I think is to mitigate this. If the fluids are different, that would be an issue with them mixing. Am I wrong as to its purpose?

LT95 Transfer Case Oil Balance Hose Kit - KLR-OBL

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Yes mine migrates so I made my own balance tube setup. 15-40 in engine , g,box and t,box. Its an ex Army LT95 A I got from the auctions and swapped out the early one I had.

The Ashcroft T,box I mentioned is the one behind the LT77. I think its an LT 230 behind my two 200TDI,s. So I have two different oils there with ATF in the T,box

For those that have not seen one.
https://live.staticflickr.com/65535/...85219668_c.jpgIMG_2871 by Keith Cree, on Flickr

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Originally Posted by 123rover50

Yes mine migrates so I made my own balance tube setup. 15-40 in engine , g,box and t,box. Its an ex Army LT95 A I got from the auctions and swapped out the early one I had.

The Ashcroft T,box I mentioned is the one behind the LT77. I think its an LT 230 behind my two 200TDI,s. So I have two different oils there with ATF in the T,box

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This is going to sound like a really silly question, but how did you determine it was migrating? Low oil level in the gearbox and the tranfer case becoming over-full?

Now for the section where I really embarrass myself! Part of the challenge I have is that my head is saying "the gearbox isn't right", however I've not got access to any other vehicles with older gearboxes like the LT95. As such, once you've finished laughing at me filming this, and asking questions, here we go!

https://youtu.be/sF20nkmJDss

1. Going up the gears, this is as fast as you can change without then crashing really harshly. Is this normal?
2. When shifting down gears, such as this into second if I don't double clutch like this it would grind badly, I assume this isn't normal?
3. There is a notable extra noise from the vehicle when in neutural and the clutch out, I assume this is just normal noise of the gearbox turning.
4. Not really a question, same point as 1.
5. Shows a gear change 2->3 which I did too quickly and so crashed in. Should I be able to change this quickly, or am I expecting too much?
6. Shows a change 3->2 whilst slowing down, and you can't get second without double clutching the box. (I mean I could've crashed it in, but my double clutching practice is paying off)
7. Same as 5. changing 2->3 too quickly causes it to crash in. Normal?

Just to say thanks again to all for helping out someone new to the joys of Perentie ownership! For what its worth I'm not a complete idiot, I have figured out the diff-lock is in fact working, for some reason the switch on the transfer case isn't connected to anything, so I'm going to have to do some wire tracing to figure out whats gone awry there.

Thanks all!

Alex

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Originally Posted by alexp789

...how did you determine it was migrating? Low oil level in the gearbox and the tranfer case becoming over-full?

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I'm speaking from the experience of owning a Toyota Troop Carrier. Similar issue. Transfer case overflows through the breather, blows out from under the vehicle and all over the rear window. Of course you pull over wondering what the heck is going on. As you have reasoned, stick you finger in the gearbox filler and feel no oil. Undo the transfer case filler and oil gushes out. In the case of the Toyota the cause is a worn seal between the gearbox and transfer case. The obvious solution is replace the seal - the easy solution is a bypass hose - or do both! I remember reading somewhere the problems are compounded where vehicle design has a transfer case sump sitting lower than the gear box sump - better design has the two sumps at the same level with easy flow between the two units. Won't go into the effort required to find enough replacement oil in a small outback town.