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  #1  
Old November 12th, 2014, 10:15 AM
lbwhotrod
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Les Wlton
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Borg Warner Help

Yesturday, my D90 developed some issues. If I am driving is a straight line and accelerating, all is good. I let off the pedel, the entire truck shakes. I put the truck in N and the shake does not change. When I make a turn a rotational squeak is heard, loudly. It sounds like it is coming from my transfer case and I can feel squeak in my rear drive shaft.

I have already ordered a new chain and viscous coupling as it is coming up on 90k miles. All busings, shocks, u-joints, brakes have been replace with new with the past six months.

I'm 80% sure that the issue is the viscous coupling, can anyone confirm. My main issue is that parts support is 3-4 week wait time at my location, and if I need somthing else I will get it ordered ASAP. Thank you guys.

1991 D90, 200TDI, Manual with BG T-case. No lift, stock axles and gearing.
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1991 D90. Love the personality, now just need to give her new head lights, lift up the front and rear, a nose job and something to dress up the tail.

200TDI, LT77, BW t-case.
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  #2  
Old November 12th, 2014, 11:13 AM
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Bill Adams
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I would look at the drive shaft joints first
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1966 109 5 door wagon 300Tdi "spermaceti fueled"
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  #3  
Old November 12th, 2014, 11:24 AM
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Chris
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You replaced the Lt230 transfer case with a Viscous coupling from a RRC?
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A friend of mine runs a land rover / range rover specialty repair shop. Based on his experience, they are capable of stopping anywhere, anytime, at any cost.

I don't know about the brakes, only their unreliability.
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  #4  
Old November 12th, 2014, 05:22 PM
lbwhotrod
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Les Wlton
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I have already checked the u joints. My d90 came with the borg warner transfer case.
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1991 D90. Love the personality, now just need to give her new head lights, lift up the front and rear, a nose job and something to dress up the tail.

200TDI, LT77, BW t-case.
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  #5  
Old November 12th, 2014, 06:09 PM
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Bill Adams
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Doubt it is the VC. Maybe a bearing. I would probably just swap in a known good transfer case rather than rebuild. I would consider the LT230 for its manual center differential lock rather than the viscous coupling Borg Warner type.
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1966 109 5 door wagon 300Tdi "spermaceti fueled"
1994 RRC LeWiB "ruining the air behind me"
1968 2A 88

All my troubles are Rover
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  #6  
Old November 13th, 2014, 07:41 AM
lbwhotrod
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Les Wlton
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I would love to put in a LT230 but I dont have parts availiblity for the swap out and shipping a T-case out to my location is not possible.
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1991 D90. Love the personality, now just need to give her new head lights, lift up the front and rear, a nose job and something to dress up the tail.

200TDI, LT77, BW t-case.
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  #7  
Old November 13th, 2014, 08:05 AM
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There is no way that you are in a more Defender-free area in Spain than we are here in DC. Cripes you are minutes from the Rock where there are fleets of the darn things
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1966 109 5 door wagon 300Tdi "spermaceti fueled"
1994 RRC LeWiB "ruining the air behind me"
1968 2A 88

All my troubles are Rover
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  #8  
Old November 13th, 2014, 02:16 PM
lbwhotrod
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Les Wlton
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Not sure where you have been, but defenders are not as abundant as they used to be. Part stores are hard to work with and that's if my translators can get the parts right. Also, it is illegal to modify your vehicle in Spain, so changing transfer case is out of the picture. I have to keep it as stock as possible so that I can bring it back to the states. I only have 18 months left here in Spain and then I can go crazy.

I want to upgrade, but until I am back in the states; its not worth the risk.
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1991 D90. Love the personality, now just need to give her new head lights, lift up the front and rear, a nose job and something to dress up the tail.

200TDI, LT77, BW t-case.
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  #9  
Old November 13th, 2014, 03:40 PM
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I'm just surprised that some removed a LT230 and swapped a BW transfer box into a Defender.
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A friend of mine runs a land rover / range rover specialty repair shop. Based on his experience, they are capable of stopping anywhere, anytime, at any cost.

I don't know about the brakes, only their unreliability.
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  #10  
Old November 13th, 2014, 05:48 PM
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Quote:
Originally Posted by Rocky View Post
I'm just surprised that some removed a LT230 and swapped a BW transfer box into a Defender.
Me too. Especially given the fact it's illegal to perform such a modification.
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  #11  
Old November 14th, 2014, 01:27 PM
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If the fluid in the transfer case had not been serviced regularly during it use, the pickup screen for the oil pump of the BW transfer case can become plugged with debris. You can see the screen for the pickup tube just behind the opening left when the drain plug is removed. Remove the drain plug clean the screen with brake cleaner or carb cleaner. Pour some fluid in the fill plug to remove debris left from cleaning. Then replace drain plug and fill with new fluid.
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  #12  
Old November 14th, 2014, 01:39 PM
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Les: humor me and the others.
Please crawl under your Defender and post pictures of your transfer case and prop shafts going to the axles. There must be some custom work under there to make it work.
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A friend of mine runs a land rover / range rover specialty repair shop. Based on his experience, they are capable of stopping anywhere, anytime, at any cost.

I don't know about the brakes, only their unreliability.
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  #13  
Old November 16th, 2014, 08:07 AM
lbwhotrod
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------ Follow up post added November 16th, 2014 02:09 PM ------



------ Follow up post added November 16th, 2014 02:10 PM ------



------ Follow up post added November 16th, 2014 02:12 PM ------

FYI, the BW Transfer case was not put into the truck. It came from factory with the transfer case. I am awaiting a new copy of build sheet and will post. There are quite a few in Europe with this configuration.
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1991 D90. Love the personality, now just need to give her new head lights, lift up the front and rear, a nose job and something to dress up the tail.

200TDI, LT77, BW t-case.
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  #14  
Old November 16th, 2014, 08:19 AM
lbwhotrod
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Les Wlton
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------ Follow up post added November 16th, 2014 02:22 PM ------

I can take pictures of the frame mounts but they are factory also. I bought the truck from the original owner with all documents from purchase. He is a 80ish old man... He told me in front of his wife that he loved the truck more than his wife.
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1991 D90. Love the personality, now just need to give her new head lights, lift up the front and rear, a nose job and something to dress up the tail.

200TDI, LT77, BW t-case.
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  #15  
Old November 16th, 2014, 08:25 AM
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Well then! That's awesome
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  #16  
Old November 16th, 2014, 12:18 PM
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I can empathize with him. That's why the wife is gone and the trucks are still here.

Reasons why a Rover is better than a woman.
A Rover is always ready to go. Well almost.
A Rover bleeds oil. I'm not saying anymore.
When you break something, a Rover doesn't get angry. It just grumbles. (That's the diff or transfer case)
You can get a Rover muddy and put it to bed without a shower.
A Rover doesn't mind if you drive another Rover.
A ring and pinion is cheaper than a diamond ring.
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  #17  
Old November 16th, 2014, 06:01 PM
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ed angel
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Check the rear u-joint at the Diff ,
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  #18  
Old November 16th, 2014, 06:05 PM
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A bad VC can put excess strain on u joints as well
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  #19  
Old November 16th, 2014, 07:03 PM
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Running a search on Euro4x4parts shows all rebuild kits for your D90 as being an LT230. So if you are concerned that non original parts might preclude importing your truck, having the BW in it might pose a problem. I would ask Doug if he thinks it would pose an issue.

Having that information the BW is in all likelihood out of a classic or a disco. Does that change parts availability for you? Probably not as you sound like you are a bit remote. Anyway, good luck.
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  #20  
Old November 17th, 2014, 01:13 PM
lbwhotrod
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Les Wlton
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Looks like I am heading down a fun road. So update on the rover. VC was locked up solid, causing the rear u joint to crack. The front is all good. I pulled the rear diff and no abnormal wear on the gears. I was able to find a u joint through some contacts on the base. After replacing the both rear u joints, VC, chain, clutch and slave cylinder; she is back on the road and running smooth. Thank you for the advice. I am hoping that I can get a few more leads and answers. IF anyone knows 100% that US customs will not care about the transfer case then I may have a lead. It is a few hours drive but might be worth it.
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1991 D90. Love the personality, now just need to give her new head lights, lift up the front and rear, a nose job and something to dress up the tail.

200TDI, LT77, BW t-case.
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