Dutchy7 · Mar 3, 2018

1990 Defender 90 200TDI
I had a leak of some more coming from my transfer box. Realized it was the nut on the intermediate gear, it was loose. What is the best way to go about tightening it as in reading it needs some specialty hands on when the transfer case is totally broken down for a makeover. Talking specialty hands on, meaning special tools and what not. Please help.

tottot · Mar 3, 2018

So the large nut in the diagram has come loose because in the past someone did not "stake" the nut [ bend the edge over at a point into a groove on the shaft ]
The basic way to set the end float would be to remove the bottom plate of the transfer box [drain oil first] Then with both in neutral you can rotate the gear by hand while tightening the nut until all free play fore and back is taken up but you can still rotate the gear by hand.
I think this would be fine but wait until someone else confirms.

jamesmartin · Mar 3, 2018

as above just tighten the nut till and free play is removed,

Dutchy7 · Mar 3, 2018

tottot said:
So the large nut in the diagram has come loose because in the past someone did not "stake" the nut [ bend the edge over at a point into a groove on the shaft ]
The basic way to set the end float would be to remove the bottom plate of the transfer box [drain oil first] Then with both in neutral you can rotate the gear by hand while tightening the nut until all free play fore and back is taken up but you can still rotate the gear by hand.
I think this would be fine but wait until someone else confirms.

Thanks for the advice. I appreciate your time!

Dutchy7 · Mar 3, 2018

jamesmartin said:
as above just tighten the nut till and free play is removed,

Thanks!

Dutchy7 · Mar 10, 2018

jamesmartin said:
as above just tighten the nut till and free play is removed,

So I snugged it down pretty well. It was making a minor grinding noise earlier when it and lose. Now it’s making it a lot more. The bar is still moving even though I tightened it down and nicked in the piece to the notch. Any further advice?

jamesmartin · Mar 10, 2018

Dutchy7 said:
So I snugged it down pretty well. It was making a minor grinding noise earlier when it and lose. Now it’s making it a lot more. The bar is still moving even though I tightened it down and nicked in the piece to the notch. Any further advice?

it would seem a bearing is worn, if its just play removing it makes a good box,

Dutchy7 · Mar 10, 2018

jamesmartin said:
it would seem a bearing is worn, if its just play removing it makes a good box,

So just keep tightening it ? It’s when I’m driving I can see it moving from the middle console board taken out and I was afraid of it being a bearing. Is it just me taking the intermediate gear out and dropping the gears to replace the bearings and putting back in while the t case is still mounted?

jamesmartin · Mar 10, 2018

Dutchy7 said:
So just keep tightening it ? It’s when I’m driving I can see it moving from the middle console board taken out and I was afraid of it being a bearing. Is it just me taking the intermediate gear out and dropping the gears to replace the bearings and putting back in while the t case is still mounted?

if you removed all the play and its noisier then it must be a bad bearing, or a worn case if shaft moves, it would need box removing to fix either

Dutchy7 · Mar 10, 2018

jamesmartin said:
if you removed all the play and its noisier then it must be a bad bearing, or a worn case if shaft moves, it would need box removing to fix either

I thought I took out all play but I wasn’t sure if
I could tighten it until I couldn’t tighten anymore as well as the gears still being able to move. So tighten it until I can’t tighten it while still allowing the gears to move?

jamesmartin · Mar 11, 2018

Dutchy7 said:
I thought I took out all play but I wasn’t sure if
I could tighten it until I couldn’t tighten anymore as well as the gears still being able to move. So tighten it until I can’t tighten it while still allowing the gears to move?

you are crushing a spacer you will need some force ,try again till free play is just removed, if its still noisy its box off

Dutchy7 · Mar 11, 2018

jamesmartin said:
you are crushing a spacer you will need some force ,try again till free play is just removed, if its still noisy its box off

Ok I’ll put some force behind it this time until I can’t turn the nut anymore. Then see what happens. By play I have none from front to back but I can still roll the gears by hand. Is that correct? Thanks for the assistance.

jamesmartin · Mar 11, 2018

Dutchy7 said:
Ok I’ll put some force behind it this time until I can’t turn the nut anymore. Then see what happens. By play I have none from front to back but I can still roll the gears by hand. Is that correct? Thanks for the assistance.

no ,play is front to back ,it should roll or rock freely,if you tighten it so it wont ti\urn easily you will soon destroy the bearings

Dutchy7 · Mar 11, 2018

jamesmartin said:
no ,play is front to back ,it should roll or rock freely,if you tighten it so it wont ti\urn easily you will soon destroy the bearings

Ok. Then I have to loosen it and that maybe the cause as to why it’s making a grinding noise. If I’m loosing fluid from those holes. I’m assuming back o rings?

jamesmartin · Mar 11, 2018

Dutchy7 said:
Ok. Then I have to loosen it and that maybe the cause as to why it’s making a grinding noise. If I’m loosing fluid from those holes. I’m assuming back o rings?

if your loosing fluid from the intermediate shaft at the front its case wear and o ring at the rear its unheard of

Dutchy7 · Mar 11, 2018

jamesmartin said:
if your loosing fluid from the intermediate shaft at the front its case wear and o ring at the rear its unheard of

Great. Bigger problem then I can handle. It wasn’t the o ring in the rear. I think it was the looseness of the nut. I’m not sure anymore, will most likely take it to a garage and pay the price.

Dutchy7 · Mar 11, 2018

jamesmartin said:
if your loosing fluid from the intermediate shaft at the front its case wear and o ring at the rear its unheard of

One last question if you don’t mind. So when I was driving I could still see the intermediate bolt and the nut still moving. Is that bolt suppose to stay still when driving? If it is then it’s not right enough. I strong armed it down pretty good and the gears were still able to move freely. Also the leaking of the fluid decreased then what it was before.

jamesmartin · Mar 11, 2018

Dutchy7 said:
One last question if you don’t mind. So when I was driving I could still see the intermediate bolt and the nut still moving. Is that bolt suppose to stay still when driving? If it is then it’s not right enough. I strong armed it down pretty good and the gears were still able to move freely. Also the leaking of the fluid decreased then what it was before.

if intermediate shaft was moving it would suggest it wasnt tight or case is very worn

Dutchy7 · Mar 11, 2018

jamesmartin said:
if intermediate shaft was moving it would suggest it wasnt tight or case is very worn

So the shaft not gears are moving front to back so then I would have to tighten it some more ? Sorry my brain isn’t gonna come off this unlesss I figure it out because I do not want to spend the money they are going to charge me here in Texas.

jamesmartin · Mar 11, 2018

Dutchy7 said:
So the shaft not gears are moving front to back so then I would have to tighten it some more ? Sorry my brain isn’t gonna come off this unlesss I figure it out because I do not want to spend the money they are going to charge me here in Texas.

shaft shouldnt move gear might if too loose back and forward

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