Datatek
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Access not easy on the diesel especially if you have not done it before.
P38A P38 2.5 dse engine noise?
- Thread starter BDC
- Start date
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Datatek
Well-Known Member
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- Near Poitiers SW France
Ok it turns out that the transmission problem is real and not a battery charge issue.
I’m currently not driving it anymore to make things not worse.
It started with output shaft message, that went away and it actually never came back. To be sure I changed the filter and oil again. Found nothing in the sump to worry about, oil looked light brown.
Shifting is a bit better but still a bit off but nothing too bad. But it started making a bunch off noises especially noticeable when hot. I could more or less locate where the noise is from, it looks like it’s coming from where the box and the transfer case meet.
I called a local gearbox specialist and he quoted 2500-3000€ that’s including labour to remove and re-install the gearbox.
It’s a diesel so it has the zf hp 22. I understand that the 4.6l uses a better gearbox and it should work on a diesel as well with some modifications.
Is correct to assume that if using the 4.6 gearbox I only need to keep the diesel bell housing and torque converter?
Also I would have to source a good used one to start with or I’m at risk of having the same issue again.
Any advice or suggestions? I’m weighing of the revised gearbox vs a hp24 2nd hand.
I’m currently not driving it anymore to make things not worse.
It started with output shaft message, that went away and it actually never came back. To be sure I changed the filter and oil again. Found nothing in the sump to worry about, oil looked light brown.
Shifting is a bit better but still a bit off but nothing too bad. But it started making a bunch off noises especially noticeable when hot. I could more or less locate where the noise is from, it looks like it’s coming from where the box and the transfer case meet.
I called a local gearbox specialist and he quoted 2500-3000€ that’s including labour to remove and re-install the gearbox.
It’s a diesel so it has the zf hp 22. I understand that the 4.6l uses a better gearbox and it should work on a diesel as well with some modifications.
Is correct to assume that if using the 4.6 gearbox I only need to keep the diesel bell housing and torque converter?
Also I would have to source a good used one to start with or I’m at risk of having the same issue again.
Any advice or suggestions? I’m weighing of the revised gearbox vs a hp24 2nd hand.
Datatek
Well-Known Member
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- 45,749
- Location
- Near Poitiers SW France
Unless you are towing or off roading I wouldn't bother with the HP24, just gave the one I had away.
There are 3 versions of the HP24 plus early and late. The late version uses the same casing as the HP22. Mark has just discovered that the input shaft length may be different, this depends on year and which torque convertor was fitted on the 4.6. The oil pump may also have to be changed. The diesel bell housing and torque convertor have to be used.
Ashcroft Engineering is the go to place for a reconditioned box and they can arrange fitting of an exchange unit.
Datatek
Well-Known Member
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- 45,749
- Location
- Near Poitiers SW France
The problem is getting it out from under the car, I don’t have a service pit. I did remove my engine before, it would have been easier hence I’m looking to get it replaced for me.
After a bit more investigations it looks like the transfer case is the culprit rather than the auto box.
I noticed Ashcroft have rebuilt kits and chains available.
Did anyone here already attempt an overhaul of the Borg Warner transfer case? If so is it doable without special tools?
I’d fancy doing it myself to keep the cost down.
I Asked for prices for a replacement Tc but without vat but with import duties included it’s already 2000€ + installation cost.
I noticed Ashcroft have rebuilt kits and chains available.
Did anyone here already attempt an overhaul of the Borg Warner transfer case? If so is it doable without special tools?
I’d fancy doing it myself to keep the cost down.
I Asked for prices for a replacement Tc but without vat but with import duties included it’s already 2000€ + installation cost.
Grrrrrr
Technician, Bodgit & Scarper Ltd
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- Buckinghamshire, UK. ('95 DT)
After a bit more investigations it looks like the transfer case is the culprit rather than the auto box.
I noticed Ashcroft have rebuilt kits and chains available.
Did anyone here already attempt an overhaul of the Borg Warner transfer case? If so is it doable without special tools?
I’d fancy doing it myself to keep the cost down.
I Asked for prices for a replacement Tc but without vat but with import duties included it’s already 2000€ + installation cost.
I looked at this some years ago but by the time I added the cost of all the parts up it was about £100 shy of what Ashcrofts were charging for a fully refurbed transfer box with all the parts done. So I dug out the £650 and paid it.
The only issue was they hadn't polished the flange where the seal sits on the output shaft and a few months later it was ****ing ATF. I replaced it a few times before I realised why it was failing. I stuck it on a lathe and eith sone very fine Wet and Dry and liberal coating of oil I polished it up then refitted with a new seal. Been golden ever since. You really notice the difference of a new chain when engine braking down hills.
So go Ashcroft but make sure they polished where the seals sit!
Thanks for the input about polishing. I actually was interested in the Ashcroft tc. But I’m not in the UK and with import duties and core deposit it is quite expensive. The core deposit equals the amount I would have to pay to ship the original back. So with current prices 850+250+ import duties =2000€
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If it's a "temporary import for repair", then you should normally get the duties back when it leaves the UK again. Same with VAT.
Had the same thing a few years back shipping Motorola demo kit to various non-EU countries. It a case of getting the paperwork correct. Any good quality courier should be able to help do it properly.
Had the same thing a few years back shipping Motorola demo kit to various non-EU countries. It a case of getting the paperwork correct. Any good quality courier should be able to help do it properly.
Grrrrrr
Technician, Bodgit & Scarper Ltd
- Posts
- 19,782
- Location
- Buckinghamshire, UK. ('95 DT)
JFC.
Might be worth a post on LZ courier service. If someone like @Mark Piercy was heading over the Channel he might get away with saying it is his spare in the boot if anyone asks.
Datatek
Well-Known Member
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- Near Poitiers SW France
Or they may find themselves with a heap of problems with customs
Just a quick update. I found a 2nd hand transfer case locally for cheap (200euro). I've brought it to a specialist to have a look at it before installation. It appears to be in really good condition according to the repair guy, even the chain is still ok. I checked the oil and filter and both looked like new, and now it's confirmed. So hopefully he can close it up quickly and we're back on the road.
