I have a 1994 disco and the transfer is blowing when shifting between Drive and R. Also the blow appears when the box shifts between 1,2,3 and 4th gears, but the blow is veery, very small.

I lifted the car yesterday, and manually turnetforward and backward the front wheels. The axleturned properly, and then I went under the car and again turned manually the wheels while I put my hand in the transfer andI could "feel" the blow. It seems that the gears that connect tre transfer and the front axle have problems. I seems that the transfer is not "always engaged" with the front shaft.

Any ideas? Common problem?

Thanks for your help!!!

 

What do you mean by "BLOW" ?
Mike

 

Sorry, my english is not good.... I tried to say that the sound that I hear is like hitting the transfer with a very, very big hammer....

Somehow, the transfer case is not 100% engaged with the front axle. For example, if I liftthe car, I can rotate both front wheelsclockwise and counterclockwiseabout 20 degrees without moving any component within the transfer. The front shaft also moves according to the wheel movement, but it seems that the shaft is not engaged with the transfer because it moves freely. When the wheel is rotated more than 20 degrees, you can feel that something within the transfer engages, and in that moment you need to rotate the wheel a little stronger.If you put the hand int the transfer case, exactly in that moment you can feel that somethingiscrankingwithin.That little crank sounds like a hammer blow when you shift between D and R and the engine is running idle.

Thanks Mike for your help!!

 

Are you sure it is the t/casee that is making the noise or causeing theblow? How about the front diff, could you have broken a spider gear causing this slock you are talking about?
When you ar turning the front wheel. is your t/case in High or High Lock?
Mike

 

Bulletin No: 37/20/96
Subject: Gearbox Mainshaft Spline Wear
Affected Vehicles:

Discovery LJ 178205 onwards
Discovery LJ 506525 onwards
Defender LD 976480 onwards

Detail:

Some customers may complain of clonks and backlash in the transmission system. This may be due to gearbox/mainshaft spline wear. The clonk/backlash will be most apparent in stop/go traffic under overrun conditions or when maneuvering the vehicle during parking, etc. From transfer box number 28D 460996 F (Discovery) and 22D 461124 F (Defender) all factory built LT230 transfer boxes have a revised design of input gear, featuring lengthened splines and cross drilled oil feed holes. This modification eliminates the requirement for an oil feed disk (bulletin H415) and eliminates input gear/mainshaft spline fretting/wear. Coincident with this change, the transfer box identification number has been raised to Suffix "F".

 

The front diff? You mean the diff that is whithin the front axle? Negative the front axle is OK, If you touch the front axle while turning the wheel, you can feel that the axle is turning smoothly, without problems. I turned the wheels while the transfer was in High anddiff Lock was off.

I did not turn the wheels withdiff lock, I forget to do that, but the blow is present when the diff lock is engaged, the engine is running idle and shifting between R and D. Also, when the car is running, the blow is present when the transfer shifts between 1,2,3 and 4, but in that case, the sound is not like a hammer blow, it is smaller... Also, I have noticed that the sound is bigger when the engine is not pushing the car and the transfer shifts. For example, when you accelerate for a couple of seconds, the gearbox downshifts, and then it upshifts again. If you stop accelerating in the exact moment of the upshift, the sound appears.

Here is a picture of the place in the transfer that I touched while turning the wheels.

 

Here is the pic

 

Trying to upload the pic....

[IMG]local://upfiles/5579/6D8AD348AF1D45A5A249E6FBB1023395.jpg[/IMG]

 

Sounds like it may be time to drain the oil, maybe remove an inspection plate and look for damage.
Mike