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Old April 19th, 2015, 09:58 PM
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Toughest trail fix

What's the toughest trail (or camp site) fix you have undertaken?

Before this weekend I'd have said a front diff or one or more front axle shafts.

But this weekend Lavender and I swapped out a transfer case on his D90 which I think ups our limit to the crap we'll do to get some wheeling in.
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  #2  
Old April 19th, 2015, 10:02 PM
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Quote:
Originally Posted by cgalpin View Post
What's the toughest trail (or camp site) fix you have undertaken?

Before this weekend I'd have said a front diff or one or more front axle shafts.

But this weekend Lavender and I swapped out a transfer case on his D90 which I think ups our limit to the crap we'll do to get some wheeling in.
Nice! Oh wait....aren't 3 out of the above 3 examples my truck? Dammit!

(Though Huff has me beat on sheer frequency of front axles/CVs).
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  #3  
Old April 19th, 2015, 10:05 PM
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Haha, haven't done a transfer case but have done front and rear axles along with rear third. How long did it take you to swap the transfer case? My guess five hours
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Old April 19th, 2015, 10:23 PM
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Did you just happen to have a spare?
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Old April 19th, 2015, 10:28 PM
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Galpin probably had two
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Old April 19th, 2015, 10:44 PM
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Two times busted bead on two different tires by a random root in sack deep mud at MAR 2006.

Worst one I had to deal with was all motor and trans mounts broken at the same time on a trail in Colorado. Luckily there was some steel cable and connector thingies in the back of my truck so we were able to tie it in place and ratchet strap the entire gaggle so it stayed secure. Probably stronger than stock, but I wanted to keep it original so it got fixed.
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  #7  
Old April 20th, 2015, 03:19 AM
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I'm still trying to get my mind around how you had a spare TC to put in on the trail...
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Old April 20th, 2015, 06:37 AM
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They didn't....my guess is Galpin broke something, then they used his TC
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Old April 20th, 2015, 06:59 AM
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I thought the LT230 was the toughest part in the Defender. How did you guys break one?!
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Old April 20th, 2015, 07:22 AM
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Damn, that Tcase could not have many miles on it. It was a new rebuilt AB unit installed by Arlington motor cars prob 5k before you picked it up from Paul. I'm wondering if the 471's and highway miles is the issue?
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  #11  
Old April 20th, 2015, 08:27 AM
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My oil pump lost pressure and I changed the front cover in Moab, at night and in the rail. Oh the joy...
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Old April 20th, 2015, 08:33 AM
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I changed a tcase in a gravel parking lot in Mass after breaking down on Mass pike. Did the job with tools I had with me. I tried jacking it up into place but in the end took the floors and tunnel out and curled it up into position.
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Old April 20th, 2015, 09:12 AM
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Quote:
Originally Posted by Ray_G View Post
I'm still trying to get my mind around how you had a spare TC to put in on the trail...
Lav drove Galpins truck back to my house in Springfield to retrieve one of my spare TC's. I had a 1.2 and a 1.6 to pick from...

Kent
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Old April 20th, 2015, 09:14 AM
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man - makes my diff pull and axle replacement look easy. Had snapped rear axles, but I had a new axle, so had to pull the diff to get pieces out of it. Worst part was scrounging up enough oil (non-40 weight) just to get it off the trail and home. Then changed out and flushed again, putting in 90wt
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Old April 20th, 2015, 09:31 AM
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Quote:
Originally Posted by nathanwind View Post
Nice! Oh wait....aren't 3 out of the above 3 examples my truck? Dammit!

(Though Huff has me beat on sheer frequency of front axles/CVs).
Yes, I own the frequency record for breaking but Lav you definitely win the most catastrophic breaks!
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Old April 20th, 2015, 09:35 AM
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Jeep. All of the front axle control arms broke. Well I take that back, the panhard bar didn't break but the uppers and lowers snapped like a twig.

A combination of chains, ratchet straps, wood, duct tape, and zip ties were used. Got it to a nearby shop and welded/reinforced the control arms. Was enough to get it home (the TJ control arms are designed to flex so reinforcing them means something else will break).

Head gasket. That sucked.
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  #17  
Old April 20th, 2015, 09:46 AM
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Quote:
Originally Posted by 85Red110 View Post
Lav drove Galpins truck back to my house in Springfield to retrieve one of my spare TC's. I had a 1.2 and a 1.6 to pick from... Kent
so did they put my transfer case in or David's
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  #18  
Old April 20th, 2015, 10:00 AM
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Quote:
Originally Posted by 85Red110 View Post
Lav drove Galpins truck back to my house in Springfield to retrieve one of my spare TC's. I had a 1.2 and a 1.6 to pick from...

Kent
^this. It was like 5-hours roundtrip to get a replacement 1.2 tcase from Kent, which is probably longer than it took to pull the old and swap in the replacement (time guesstimate by Brewie is almost spot-on). Thanks again Kent for letting me roll into your place late-night so we could salvage the weekend.

It's also worth taking note...this was ALL done so that we could salvage the remaining weekend of wheeling. Which, we absolutely did...wheeled Saturday after the fix and Sunday as well! This wasn't just so we could "get home" :).



Quote:
Originally Posted by 1of40 View Post
Damn, that Tcase could not have many miles on it. It was a new rebuilt AB unit installed by Arlington motor cars prob 5k before you picked it up from Paul. I'm wondering if the 471's and highway miles is the issue?
Quote:
Originally Posted by don View Post
I thought the LT230 was the toughest part in the Defender. How did you guys break one?!
So it seems to be what failed in the tcase was the crosspin (#28 in the below pic). Apparently this tcase wasn't even that old, maybe 20k miles on it (and supposedly a rebuild from AB as Clay pointed out). So not a catastrophic failure per se, but rather a weak point letting loose it seems. Who knows....but it does seem to be a "known" issue for LT230s which is why Ashcroft makes this upgraded replacement crosspin:
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  #19  
Old April 20th, 2015, 10:57 AM
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Quote:
Originally Posted by nathanwind View Post




So it seems to be what failed in the tcase was the crosspin (#28 in the below pic). Apparently this tcase wasn't even that old, maybe 20k miles on it (and supposedly a rebuild from AB as Clay pointed out).
Isn't the Borg-Warner crosspin also an upgrade?

.
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  #20  
Old April 20th, 2015, 11:01 AM
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Quote:
Originally Posted by nathanwind View Post
So it seems to be what failed in the tcase was the crosspin (#28 in the below pic). Apparently this tcase wasn't even that old, maybe 20k miles on it (and supposedly a rebuild from AB as Clay pointed out). So not a catastrophic failure per se, but rather a weak point letting loose it seems. Who knows....but it does seem to be a "known" issue for LT230s which is why Ashcroft makes this
Normally caused by drivers spinning wheels with the diff unlocked.
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