Disco 1 Help please, think I've ooopsed up my transfer box!

This site contains affiliate links for which LandyZone may be compensated if you make a purchase.

Jasonmichael

Well-Known Member
Posts
256
Location
Oldham
Hello guys,

I think I've either done something drastically wrong in the rebuild or missed something or....?:(:(
I rebuilt it back end of last year (then my back again decided it wouldn't play anymore) fast forward to last weekend when I was well enough to put it back into its rightful place.

So Disco is on 4 ramps, transfer box re-installed, whilst everything was apart and accessible, the autobox was also treated to a new filter and new fluid. New fluid put into the transfer box (2.5L) and all linkages reattached for the high/low ratio & diff lock. Things going swimmingly I think.

Now before I put the props back on I thought I'd start it up & let it go through the gears to allow the autobox to circulate the fluid around, so start up, engage D,3,2,1 & back & forth, everything was fine so I thought lets engage the transfer box and see if it works. High / low were selected, no weird noises to report, diff lock in high / low all worked with no untoward noises. By this point I was starting to feel happy at a job well done, both boxes were working as they should and....and NO LEAKS :)

Engine switched off, I get underneath and start to contemplate putting the propshafts back on, now for some reason, I don't know why I just put my hand on the rear output flange and it was hot, bloody hot. Not hot enough to burn, but hot enough that you couldn't keep your hand on it??? I then thought 'Oh dear, what have I done' put my hand on the front output flange to compare and that was fine, not hot at all???

The only thing I think it could be is the bearing on the rear output getting overly hot for some reason??? The bearing was new and was pre-greased & I doused everything with gear oil before putting the box back in.

Could I have -

A) Over tightened it to the shaft?
B) Got a duff bearing?
C) Help I'm running out of ideas:(

TIA
 
Hello guys,

I think I've either done something drastically wrong in the rebuild or missed something or....?:(:(
I rebuilt it back end of last year (then my back again decided it wouldn't play anymore) fast forward to last weekend when I was well enough to put it back into its rightful place.

So Disco is on 4 ramps, transfer box re-installed, whilst everything was apart and accessible, the autobox was also treated to a new filter and new fluid. New fluid put into the transfer box (2.5L) and all linkages reattached for the high/low ratio & diff lock. Things going swimmingly I think.

Now before I put the props back on I thought I'd start it up & let it go through the gears to allow the autobox to circulate the fluid around, so start up, engage D,3,2,1 & back & forth, everything was fine so I thought lets engage the transfer box and see if it works. High / low were selected, no weird noises to report, diff lock in high / low all worked with no untoward noises. By this point I was starting to feel happy at a job well done, both boxes were working as they should and....and NO LEAKS :)

Engine switched off, I get underneath and start to contemplate putting the propshafts back on, now for some reason, I don't know why I just put my hand on the rear output flange and it was hot, bloody hot. Not hot enough to burn, but hot enough that you couldn't keep your hand on it??? I then thought 'Oh dear, what have I done' put my hand on the front output flange to compare and that was fine, not hot at all???

The only thing I think it could be is the bearing on the rear output getting overly hot for some reason??? The bearing was new and was pre-greased & I doused everything with gear oil before putting the box back in.

Could I have -

A) Over tightened it to the shaft?
B) Got a duff bearing?
C) Help I'm running out of ideas:(

TIA
That's the one with the handbrake drum on it, was the handbrake dragging.
How tight is the flange/drum to rotate by hand?
Not right up on how it is constructed, but It sounds as if there could be too much preload on taper roller bearings.
I know there is mention of shims in the manual.
 
Hi Gazbo,

I hadn't put the handbrake drum back on, I was just seeing if the xfer box worked without everything on it at first. The bearing I'm on about isn't a taper one its just the normal one as per the diagram below No.4. No Shim, just a spacer No. 3. and a circlip to hold it in place.

cadbia5a.gif
 
Thanks James, I don't know how I could have assembled it incorrectly, I followed the diagram and instructions very carefully. With the transfer box back in situ James, would it be possible to remove just the rear assembly??? Or is it box out again???
 
Last edited:
Back
Top