sh---ing noise in transfer box after changing gearing

OLDUN · Oct 30, 2015

Hi everyone - changed gearing from 1.2 to 1.4 on my 300tdi 110 and the noise appeared - louder the faster the vehicle goes - over and above the engine noise. The garage - who I have used for many years and are very experienced - took it back and opened the transfer box and re-did it - but the same noise. Has anyone any ideas please. The box has done 2,000 miles and was purchased from Ashcrofts about 18 months ago and the replacement gearing came from them also - they have no idea what might be wrong. Am about to have the original gearing put back!!!.

Thor1950 · Oct 30, 2015

OLDUN said:
Hi everyone - changed gearing from 1.2 to 1.4 on my 300tdi 110 and the noise appeared - louder the faster the vehicle goes - over and above the engine noise. The garage - who I have used for many years and are very experienced - took it back and opened the transfer box and re-did it - but the same noise. Has anyone any ideas please. The box has done 2,000 miles and was purchased from Ashcrofts about 18 months ago and the replacement gearing came from them also - they have no idea what might be wrong. Am about to have the original gearing put back!!!.

so you put it back to original gearing then.

bankz5152 · Oct 30, 2015

Make a video of the noise and post it up

OLDUN · Oct 30, 2015

Not yet but cannot see any other option. It is out of the 110 at the moment - as put in another transfer box from another 110 I have as was leaving later in the day for Turkey

OLDUN · Oct 30, 2015

bankz5152 said:
Make a video of the noise and post it up

Thanks for the suggestion but the box is now out of the 110 and has been sitting on the barn floor for last 4 weeks

Brown · Oct 30, 2015

How long did you have it running with the new gears in? Was there any sign of them getting quieter as they bedded in together? Or was it getting louder, or staying the same? Was the oil level OK?

jamesmartin · Oct 30, 2015

OLDUN said:
Hi everyone - changed gearing from 1.2 to 1.4 on my 300tdi 110 and the noise appeared - louder the faster the vehicle goes - over and above the engine noise. The garage - who I have used for many years and are very experienced - took it back and opened the transfer box and re-did it - but the same noise. Has anyone any ideas please. The box has done 2,000 miles and was purchased from Ashcrofts about 18 months ago and the replacement gearing came from them also - they have no idea what might be wrong. Am about to have the original gearing put back!!!.

what is opening t/box and re did it mean exactly

lynall · Oct 30, 2015

Did you know you can refit the splined input gear back to front and it makes some very interesting noises?

OLDUN · Oct 30, 2015

Brown said:
How long did you have it running with the new gears in? Was there any sign of them getting quieter as they bedded in together? Or was it getting louder, or staying the same? Was the oil level OK?

Did about 500 miles - noise levels remained the same throughout.

Brown · Oct 30, 2015

Hmm. Enough to bed in a bit. Some are just noisier than others. Even though the components are made to quite tight tolerances they've all got little personalities of their own.

It's hard to say what's wrong without taking things apart again. I'd take the thing indoors and have the oil pan off and rotate the components gently, feeling for any slack or roughness or any movement of the gears on the shafts or the shafts in the holes and so on. Any oddly formed teeth, unusual wear patterns developing, spare bits of metal knocking about in the sump, a lot of metal bits in the oil as it's drained, all the usual things that might indicate a gearbox is in trouble. If it's all smooth and there is no untoward movement I'd run it a bit longer and see what happens.

jamesmartin · Oct 30, 2015

OLDUN said:
Did about 500 miles - noise levels remained the same throughout.

which gears have you changed and with what ,there are 3 types of 1.2 gears at least

OLDUN · Oct 30, 2015

jamesmartin said:
which gears have you changed and with what ,there are 3 types of 1.2 gears at least

Ashcrofts supplied- 1.4 gear set plus FTC 5089 26 tooth cross drilled input gear.

OLDUN · Oct 30, 2015

Brown said:
Hmm. Enough to bed in a bit. Some are just noisier than others. Even though the components are made to quite tight tolerances they've all got little personalities of their own.

It's hard to say what's wrong without taking things apart again. I'd take the thing indoors and have the oil pan off and rotate the components gently, feeling for any slack or roughness or any movement of the gears on the shafts or the shafts in the holes and so on. Any oddly formed teeth, unusual wear patterns developing, spare bits of metal knocking about in the sump, a lot of metal bits in the oil as it's drained, all the usual things that might indicate a gearbox is in trouble. If it's all smooth and there is no untoward movement I'd run it a bit longer and see what happens.

Transfer box was not making knocking or sharp noises - but a smooth rubbing sound but louder the faster the vehicle went and really drove me crazy - under 15 mph could not hear anything.

jamesmartin · Oct 30, 2015

OLDUN said:
Transfer box was not making knocking or sharp noises - but a smooth rubbing sound but louder the faster the vehicle went and really drove me crazy - under 15 mph could not hear anything.

could be hand brake shoes or quite often people put too long a bolt in the top front securing t/box to gear box, bolts should only be 40 mm long

Brown · Oct 30, 2015

jamesmartin said:
could be hand brake shoes or quite often people put too long a bolt in the top front securing t/box to gear box, bolts should only be 40 mm long

That's a point. You can get all kinds of funny noises from the handbrake.

OLDUN · Oct 31, 2015

jamesmartin said:
could be hand brake shoes or quite often people put too long a bolt in the top front securing t/box to gear box, bolts should only be 40 mm long

Thanks for that - does sound like the noise a brake shoes would make. I put in a transfer box from another 110 I have and the noise was no more - but the handbrake was changed also - the replacement transfer box had a drum handbrake - however the noisy one had an x-eng handbrake - could this have made the noise though does seem unlikely as it grips pretty quickly.

OLDUN · Oct 31, 2015

Brown said:
That's a point. You can get all kinds of funny noises from the handbrake.

Would a longer bolt encourage such a noise.

jamesmartin · Oct 31, 2015

a longer bolt would rub on the intermediate gear

OLDUN · Oct 31, 2015

Just been to have a closer look at the transfer box/x-eng hand brake on the floor of the barn. Turning the disc on the hand brake makes THE NOISE. The disc is loose of course so going to put the rear propshaft on to tighten the nuts to secure the disc and see if the noise is still there - if so will slacken off the cable/spring to see if it solves the problem.

wammers · Oct 31, 2015

OLDUN said:
Just been to have a closer look at the transfer box/x-eng hand brake on the floor of the barn. Turning the disc on the hand brake makes THE NOISE. The disc is loose of course so going to put the rear propshaft on to tighten the nuts to secure the disc and see if the noise is still there - if so will slacken off the cable/spring to see if it solves the problem.

Has one of the retention springs come off a brake shoe?

sh---ing noise in transfer box after changing gearing

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