Disco 1 Clunking in transfer box after a rebuild

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flatline

Active Member
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256
Location
Blackpool
My transfer box has been leaking for years and rumbling for a while too, I decided to buy a rebuild kit from ashcroft. Followed the manual but used the shims that were in it.

The vibration/rumbling has gone but now a get a clunking sound when the engine starts and when under load.

The box has got to come off again as two bolts snapped, at some point somebody tried to solve the leak as it didn't have any gaskets on, only sealant and the bolts were covered in loctite.

Any advice on appreciated :)
 
My transfer box has been leaking for years and rumbling for a while too, I decided to buy a rebuild kit from ashcroft. Followed the manual but used the shims that were in it.

The vibration/rumbling has gone but now a get a clunking sound when the engine starts and when under load.

The box has got to come off again as two bolts snapped, at some point somebody tried to solve the leak as it didn't have any gaskets on, only sealant and the bolts were covered in loctite.

Any advice on appreciated :)
@jamesmartin is the man you want to be speaking with;) What he doesn't know about transmissions isn't worth knowing
 
My transfer box has been leaking for years and rumbling for a while too, I decided to buy a rebuild kit from ashcroft. Followed the manual but used the shims that were in it.

The vibration/rumbling has gone but now a get a clunking sound when the engine starts and when under load.

The box has got to come off again as two bolts snapped, at some point somebody tried to solve the leak as it didn't have any gaskets on, only sealant and the bolts were covered in loctite.

Any advice on appreciated :)
if the box is 300 tdi onwards no gaskets should be used,gasket on the pto cover and on either output housing would create free play in the bearings, as the box uses taper bearings the input gear, intermediate gear cluster and diff unit should have no endfloat at all
 
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