I just bought a 1999 4.0L Range Rover with 113,000 miles. Purrs like a kitten! Spring Conversion Kit done! No overheating! Thank GOD! I do however have the clanking sound under acceleration or going up a hill(BORG-WARNER). I'm 99% sure its the Drive Chain in Transfer case. I'm wondering what are my options on this repair. Just the chain? Replace with same TC? Replace with different TC. Used or New? lets hear some opinions! Disco Mike has suggested replacing with a LT230. Is this a plug a play replacement? I know the shifters are different from Discos and RRs.

 

Well it seems that this part of the forum isn't nearly as helpful as the DII section. I have done some research on my own today and am basicly looking at 500 dollars to get a used transfer case delivered to me(they must be REALLY heavy!). It turns out the only 2 options are to Replace the TC completly,or replace my drive chain in my existing as I found out today the swapping the p38 TC for the D1 TC is a myth, it only fits in the Range Rover Classic, not the p38's.

I have decided to just replace my drive chain as long as my bearings and gears are in good shape like I'm expecting. I figure I have to take the TC out anyway so iI might as well take a few minutes and crack it open to see if it could get by with just a chain. I mak decision based on the fact that a used TC with around 100K on it will cost 500 dollars shipped, and its only a few thousand miles from the same failure I have now. Mine failed at 110K and thats about where most fail at.

The best price/warranty on this drive chain I've found is at

1999 Land Rover Range Rover Transfer Case Drive Chain - Borg Warner - TheAutoPartsShop

302.00 shipped with a 2 year warranty. I am going to see if AtlanticBritish.com will price match and warranty match this and buy from them if so. Haven't decided if I'm gonna do it my self or not yet. That depends on how cheap I can get the local mechanics talked down to on labor.

 

This might be of help to you.

Pretty good timing I guess haha

How To: Replace Transfer Case Drive Chain

 

Thanks! That is exactly what I needed. Instructions with Pictures! Or as my dad calls them...Destructions! haha

 

I would also check the driveshafts/ U joints,
the front in particular if you have the truck lifted then increased drive line wear will occur

 

I got Dave at Atlantic British to price match the $302.00 with free shipping. Had to settle for a 1 year warranty though, he said it's against their policy to change warranty lengths. Got it put in by a local Tranny Shop for $250 and it's running like a dream. I did have one gear that the teeth were a little worn. (Rear Flange Gear). Since the part new was over $500 and the only other option is to buy a used transfer case and hope the part inside it is in better shape, I decided to just reassemble and re install what I have. Not Too bad considering I only gve $2200 for the truck and now its up and going! Happy Trails!