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Noisy transfer box

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V8MoneyPit:
Over the last few days, the Sammy has developed a really nasty clunking noise from the transmission. Put it on stands and got under it last night. Not the safest thing to do with the engine running and in gear... but had to do it to find the noise.

Turns out to be the 410 transfer box I put in a few weeks ago  :evil: I am more than happy that the seller didn't know of any problems, but it is one of those annoying things. At least it's an easy job to get it out.

I suspect it's the intermediate shaft needle bearings since I can't find any play in the output flanges. Can anyone tell me if the needle bearings are the same as the ones in the 413 transfer box? If so, I'll split them both open and build one good one from the two.

V8MoneyPit:
The wonder of main dealers, eh?

I'm rebuilding the transfer box and wanted to buy shims to set the clearances on the input and output shafts. The local main dealer could not help without a VIN number..... it's a 410 box fitted to a 413.... like I'm going to have a VIN number!!!

Anyway, he faxed me a copy of the exploded view and there are no shims listed at all! So, where do I get the shims from if they aren't even listed by the dealer?

minimog:
theres no shims on the input shaft there is two in the intermediate shaft
just striped mine and found the input rear bearing was shot   check for backlash in the diffs and t case also check the u j on the props

V8MoneyPit:
It appears there are 3 different designs of 410 transfer box. Mine certainly has shims on both input and output shafts to set the endfloat.

The centre gear in mine doesn't have any shims, just standard size thrust washers.

All the bits finally arrived today, so I've a got a coupele of evenings work ahead to put it back together!

The noise was definately from the transfer box. With the car running in gear there was an obvious clunking from it... I'me guessing the centre shaft thrusts were worn and it was banging backwards and forwards.

The UJ's seem fine to me. If there is any play, it is only a tiny amount. And there is no more play in the propshaft splines than you would expect.

Anyway, we shall see (or hear maybe!) in a couple of days!!

Looks like I'm going to get the remains of a 410 MOT failure for free if I take it away soon. So that might prove useful  :D

rollazuki:
There are no shims shown in the genuine workshop manual, yet on most of the tranny cases Ive stripped/rebuilt(10+) there were shims in them all. More than 1 in most cases, hinting that they are shimmed up at the factory. Ive run them without shims and had no grief tho.
The intermediate shaft does wear, the bearings are usually good but the case hardening on the shaft fails, the bearings do fail after a while, but if its clunking lots, check the hi-lo selector ring on the lower shaft.

On some cases, Ive seen the teeth on the selector ring get mashed up, causing a lot of slop thru the box. Just check the centre splines, and the splines on each gear are looking OK.

One thing worth shimming is the front drive unit. If the clearances open up, the spigot on the gear can end up snapping off. well worth a shim under the gear and a clearance check.

If you need any parts let me know, Ive a few cases and front drive housings spare, but mainly only 413 internals spare(built 3 or 4, 4.16 low ratio boxes now.)

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