VERY clunky transfer box

Hi all,

Well, my drivetrain issues continue. I've got quite a lot of play in my drivetrain, which I can live with. However, what is more worrying is that when I back off the throttle above 50mph (when the drivetrain goes slack), there is a grumbly knocking noise coming from beneath my feet.

My immediate thought is the transfer box: there is no up and down play in either diff and neither diff is whining. There is a little up and down play on the transfer box front output, and when you rotate the prop by hand you can hear a load of clonking coming from inside the transfer box.

I do know that the input gear in the transfer box is absolutely fine- the clonking noise seems to be coming from the output half of the box.

The transfer box is off a s1 disco, and was very cheap.

The gearbox is new, only covered 1500 Miles.

I can have a look tomorrow- is there anything in there i can replace fairly simply, or is it a complete box replacement job?

I'm currently near Ashbourne, stopping off with my parents on my way to LRO show on Sunday. Hoping it'll last the journey. Or that I can fix it tomorrow.

Thanks in advance,
Steve

take front prop and go for a run in diff lock ,noise on overrun is usualy front diff pinion bearings , if not remove t/box sump and feek for end float on intermediate gear, which can be taken up by tighten outer nut carefully

Brilliant, thank you!

Tool your advice- the noise/ vibration is still there without the front prop. Took the sump off the t-box: end float Seems to be ok (but I'm very new to this!), but there does seem to be a lot of rotational play on the output shaft gears- i can rotate the props a good 2mm before it takes up drive in the transfer box. I'm assuming it means the transfer box has had its chips?

I did also have another thought: I recently put new springs on the back as the old ones were knackered! I went for hd heavy load springs as this summer I'm going to be doing a reasonable amount of towing and carrying heavy things. The springs aren't lifted, but do make it sit about 2" higher than it used to. Do you think this could be having an adverse effect on the prop?

You;'ve got the wrong springs if its higher than it used to be by 2inches,

You want a wide angle propshaft and probably new trailing arms,

HDstd springs are a good upgrade though, especially on the front end

The springs themselves are no higher than the old ones (i've got a picture somewhere), but the old ones were really worn and couldn't cope with the weight I have in the back. So.it's no higher than standard, but 2" higher than it used to be. (i parked next to a standard ex-mod 110 on normal height springs and it was identical.) I also reckon I've ruled out the prop shaft theory as it would be vibrating all the time if that were the case.