Transfer Case "Clatter"

[Wolf Fabrication]

Just installed a newly re-geared t-case. Swapped from 1.2 to 1.4 gears. I now have a "clatter" when I let off the accelerator pedal. I assume this might be the difference between my old gears meshing with the new 1.4s. I did adjust the end lash on the intermediate gear per the manual.

Any ideas?

[dchapman]

Sounds like the lash is not correct. Too much slop. The "clatter", or any noise, is not normal.

[Wolf Fabrication]

I agree, it's not normal. How is the lash adjusted in the LT230? The manual makes no mention of adjusting any lash, only the end lash in the intermediate gear.

[mikeslandrover]

are the taper roller bearings good? There's a crushable distance piece between them. If it's too crushed then there's clatter and it's not good for long and trouble free motoring:(

[Wolf Fabrication]

New bearings, races, and crush sleeve, torqued to specs.

[James Pierce]

I assume this might be the difference between my old gears meshing with the new 1.4s.

I had the same problem when I switched input gears from the early solid one to a latter cross drilled version. I wound up having to swap all the gears. I don't know if they develop a ware pattern with each other which causes this but it sounds like running a combination of new gears w/ old might be your problem. Probably not what you wanted to hear.:(

[Wolf Fabrication]

Sad thing is that I have a complete set of matching gears and only replaced the high range and intermediate gears!

[mikeslandrover]

Sad thing is that I have a complete set of matching gears and only replaced the high range and intermediate gears!

I think the crush sleeve is a one time thing too:(

[Wolf Fabrication]

I think the crush sleeve is a one time thing too:( It is, but at least it's cheap!

[Wolf Fabrication]

As a follow up for anyone that had this issue, after tearing down the tcase again it turned out to be the intermediate gear bearings and crush sleeve. The shaft nut was not torqued to specs. According to the rebuild manual the nut should be torqued so that no end play is felt, however, that leads to the issue noted above. Per several rebuild articles in LRM and LRO, the nut should be torqued until slight rolling tension is felt while turning the intermediate gear. I did the second method at that corrected everything.

[jaygoss]

Jonathan,

thanks for the follow-up. A lot of times folks find out the cause of their issue and fix it, then they don't post the solution/fix. I appreciate your taking the time to help someone else in the future. You're a good egg, my man.

[130Tdi]

As a follow up for anyone that had this issue, after tearing down the tcase again it turned out to be the intermediate gear bearings and crush sleeve. The shaft nut was not torqued to specs. According to the rebuild manual the nut should be torqued so that no end play is felt, however, that leads to the issue noted above. Per several rebuild articles in LRM and LRO, the nut should be torqued until slight rolling tension is felt while turning the intermediate gear. I did the second method at that corrected everything.

Jonathan- does rolling tension mean resistance to turning the gear ? Kind of like a wheel bearing, tighten till it starts to bind, then loosten a .25. In this case no letting off due to the crush sleeve. Could you email me that article ?

[Wolf Fabrication]

The article just said to turn until slight tension is felt and was careful to go real slow. Based on my recent ordeal, I would say backing off a 1/4 turn would be bad. You can't feel the same binding as a wheel bearing on the smaller taper bearings either.

I'll email you those articles.

[130Tdi]

Got them thanks.

[easy]

Jon,
Could you email me those articles as well? I think I might be having the same problem.

[Wolf Fabrication]

Jon,
Could you email me those articles as well? I think I might be having the same problem.

Sure, PM or email your address