It's time..... for a new transfer box.....

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Close up of the HD ones, made by Ashcroft
 

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I read you post and was thinking it sounds like the drive flange, I just installed some HD ones on a clients Landy. These have more splined surface area but the down side is you might wear the splines on the axle more in extreme driving conditions...the OEM ones being the sacrificial part.

I like the HD ones for the grease cap, its bigger and threaded with a rubber seal.

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I'll post a pic tomorrow of the supposedly HD ones that the previous owner fitted, and the wear! Maybe they were just gold coloured....
 
Rear drive flanges and shafts changed today - the offside was the culprit - I cannot believe the noise it made!!

I can now get diff lock too, very strange, so panic mode disengaged :)

here's the before and after shots :)
IMG_2518.JPG
IMG_2520.JPG
 
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