transfer box ? d2 td5

baileyboy40 · Oct 13, 2021

Hi everyone, need to pick some ones brains.
Broke down on the motorway yesterday, slight noise from under the car and it slowly came to a stop.
If i put it in gear and revved hard it would move slowly with noise from near the front prop.
Got it home and jacked up, checked and renewed gearbox oil, that is fine, took the from prop off, put in gear and revved, clunking noise coming from where prop joins on to gear box and no power at all to the back wheels, i live in the middle of no where in north wales and am cut off without a car, can anyone point me in the right direction ?
Thanks
Steve

marjon · Oct 13, 2021

Do you have diff lock lever in cab or the mech in the tb.

do some search’s some have.

Oh welcome

J

baileyboy40 · Oct 13, 2021

marjon said:
Do you have diff lock lever in cab or the mech in the tb.

do some search’s some have.

Oh welcome

J

Thanks Marjon, got the little lever next to the auto lever

ronsealdeath · Oct 13, 2021

D1 or D2? I would check the low range linkage ( and diff lock if it has one). Take the centre console out and drill out the rivets. Its an easy job and will help diagnose a linkage issue. It may be stuck in between hi and neutral on the t box.
If not, you can remove the front output housing in situ to inspect the box. But some people just fit a replacement box.
I can post up the procedure to remove tge output housing if needed

baileyboy40 · Oct 13, 2021

ronsealdeath said:
D1 or D2? I would check the low range linkage ( and diff lock if it has one). Take the centre console out and drill out the rivets. Its an easy job and will help diagnose a linkage issue. It may be stuck in between hi and neutral on the t box.
If not, you can remove the front output housing in situ to inspect the box. But some people just fit a replacement box.
I can post up the procedure to remove tge output housing if needed

Thanks for your help, its a 2003 td5 auto, diff locks and can move from high to low but is stiff ,would really help if you could post info

baileyboy40 · Oct 14, 2021

Update on this,
Diff lock is working and sending power to rear wheels, the noise is coming from front of transfer box, is this a recon box job or is there a repair that can be done ?

ronsealdeath · Oct 14, 2021

I dont know what your issue is but you have a bearing in the output section plus a large taper roller bearing, the race for which sits in the front housing. The gear cluster sits behind this. Its a rebuild job by the sounds of it but i am no expert, ive just rebuilt the front housing. Lt230 isnt too hard to rebuild but most fit a recon or good used box.
It may be that your centre diff has gone but these usually go when on loose surfaces spinning the wheels. They are a weak point when not locked.
Is the noise there in high and low range?

transfer box ? d2 td5

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