Transfer box leak/broke?

Hello All,

Greetings from Abu Dhabi!

I'm hoping you can lend a sympathetic ear - once again.

I was driving my Discovery (2004, 4.0L, ES, Auto) at approx 75mph in Drive with cruise control. Suddenly I heard an intermittent sharp knocking/crunching noise from what I though was the engine bay.

I pulled over and the noises disappeared completely, I pulled away slowly and the sound appeared again. I pulled over again and removed the cowling above the rad fan and refitted. The noise stopped for a short time, however once I picked up speed it re-appeared. Then I felt a couple of thuds, it continued to drive but after this point I heard a whining noise, as if a motor was winding without a belt. Got it towed back to a garage in Abu Dhabi.

We test drove it and all the crunching/cracking noises have completely gone (I took it upto the same speed as i was driving earlier). What is present is the whining noise, I selected H-L gears, it drives OK.

Man in garage has checked oils levels in gearbox etc and reckons its the transfer box (i think it is as its near just before handbrake) as he filled it and it all leaked out from the upper area, he cant say where as he can't see. Has recommended a transfer box replacement, hopefully from the scrappy.

Just wanted to know, would that be the most logical path to follow?

Your experience is very much read and valued. I did read the threads but couldn't find anything relevant to my situation.


Cheers
Deep

if its leaking then its got to be removed if it can not be fixed on the car removing the bottom plate may show the problem

Hi Martin,

Thanks will get them to try removing the plate, is it quite straight forward?

Can it be removed whilst on vehicle or does the transfer box need to come out completely?

Cheers
Deep

it can be removed in the vehicle

Hello again,

We managed to get tranfer box opened for a look inside, the engineers found the cogs were very loose and reckoned the bearing were completely gone. They also discovered metal mixed in with the oil. As parts are quite hard to source we decided to get a used transfer box.

For anyone in the UAE reading this, there are hundreds of scrap yards in Sharjah. From what they told me, they import used Land Rovers from Japan, due to their limited life they are a very good source for reliable/working parts.

Anyway, transfer box arrived this morning. There are a couple of variances on the new unit which my existing box does not have. Does anyone know if this may cause any problems? Pics attached.

1 - Top of pic - I believe this is a knock sensor - wasn't on my transfer box
2 - Left of pic - I don't know what this is
3 - Far left, the rod-like piece protrudes less than the original (no screw required there)

Oh, mechanics are going to use SAE 80/90 oil - is that OK?

OLD TRANSFER BOX



NEW TRANSFER BOX



Cheers
Deep

1 is a shift interlock jap spec stops gear selection (dont no realy when and why)
2 is the center difflock
3 no idea cant see

80/90 ok

Hi Martin,

Thanks so much for your input - I've been stuck between a mechanic that has limited knowledge on LR and a second-hand parts supplier that doesn't know a knock sensor from a shift interlock. Your input is slowly bringing my Disco back to life!

Transfer box has been installed, however the car does not start in Park but does start in Neutral. I've read that Jap and American spec normally require brake pedal depressed and P selected in order to start (my transfer box is from a Japanese import.

Having done some research some people have recommended removing the solenoid from within the interlock unit. Any other suggestions/ideas folks?

UPDATE: ENGINEER 'PLAYED' AROUND WITH THE GEAR LEVEL AND IT SEEMED TO HAVE FIXED THE PROBLEM. CAR NOW RUNNING, SELECTED H & L DRIVES. ALL RUNNING OK.

A special thanks to Martin Hollings for his input and knowledge.

All the best
Deep

Hi Deep.

You write about scrap dealers in Sharjah.

Where in Sharjah?
I’m not so familiar with Sharjah… any landmarks or phone numbers for the best scrap yards for land rovers will be appreciated.

I'm living in Oman, and have no luck finding any scrap dealers here into Landrover.

And by the way do I also need to have a replacement transfer box. Was Wadi bashing over a long stretch, so I didn't discover the unhealthy sound from probe shaft/transfer box until I got back on the paved road... and a transfer box klick sound (except when accelerating) was evident. :-(

Morten

Why are all of these posts so old?

bonnettoboot said:

Why are all of these posts so old?

Click to expand...

Cus it's an old thread