S

Slowmo

New Member
Hi guys

The journey so far

Fitting a transfer box that has been drained and the input gear removed to make it easier to slide on the gearbox main shaft.

All was going well until it came to connecting up the diff lock mechanism when I noticed that when diff lock was activated it wasn't locking as it should but instead I couldn't turn the front and rear drive flanges at the same time, I then disengaged it and it remained the same???

Anyway I decided to remove the box and take the cover plate off to reveal the mechanism and try and find out what was going on, before getting to that point miraculously it had fixed itself and I could turn both flanges at the same time and independently!

So again I put the box back on all going well again and then when connecting the diff lock it started doing it again.... In addition when activating the diff lock now it completely locks drive I can't even turn one flange on its own.

I connected up the switch and that's operating fine light comes on when diff lock engaged and goes out again.

I'm aware that these sometimes stick but as I've taken out the input gear without the gears being able to turn I can't get it back in to stick it in reverse....

Any ideas guys completely baffled here and on a deadline.

Cheers
 
when in difflock both flanges are locked together as such so wont turn indepenently , if you have just one front wheel jacked up wheel will spin out of difflock but wont in ,unless you have a rear wheel up ,no hand brake on and gear box in neutral
 
Just to clarify on what the transfer box is doing currently, I can turn the flanges in opposite directions fine and there's about an 1/8th of a turn before they lock which as I understand about right, but it locks completely if I try and turn both simultaneously.
When activating diff lock the whole thing locks up.
Cheers
 
It's a discovery transfer box for my defender wanted the higher gearing, I haven't changed any if the internal workings of the box.
The first time I removed it it was strange how simply unbolting it allowed me to then turn both flanges at the same time and diff lock totally disengaged.
The diff lock wasn't engaging properly because the diff lock switch was done up to tight so the chamfered edge couldn't overcome it.
Now as I say when diff lock is on I can't turn anything.
 
Should of said there when I loosened the switch it was working perfectly when I had the cover plate off on the floor.
Somewhere in between there and bolting it back on its developed this locking out problem
 
both flanges may turn when not in difflock as diff gears will turn meaning both flanges will counter rotate without transfer box rotating but in diff lock transfer box must unles t/box is in neutral ,whip sump off and see what jamming gears , or undo the top front bolt securing transfer box it may well be too long jamming gears , 6 bolts securing transfer box shoul be 2 front to back on drivers siide the shortest ,next shortest lowest rear to front ,next shortest next bolt up, longest bolts top passenger side and top drivers side though usually thats a stud
 
I think you've got it there James top bolt might be too long as my old one was rounded j replaced it with another and from memory it was longer if ever so slightly.
I'll take it out now and get back to you in a mo.
 
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