Indication of a Dying T-Case - Defender Source
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Old June 17th, 2013, 06:07 PM
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Indication of a Dying T-Case

What are the tell-tale signs of a t-case on it's last leg?

When they fail is it usually catastrophic? Are we talking about wheels locking up on the highway here?

Is is better to rebuild the T-case before mechanical failure?

What is the right way to rebuild one if I want stock gears? I would rather rebuild than replace with another used T-case. That way I KNOW it's solid. Also, I'm not interested in killing my highway speed any further than I already have with 4:11 gears.

Truck: '97 NAS D90 SW
Use: Light Trails/sand - no crawling
Mods: 4:11 ratio TruTracs (front & rear) with upgraded prop shafts
Tire size: Stock

Thanks is advance for your input.
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Old June 17th, 2013, 06:19 PM
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The only non idiot (run out of oil, drive with diff locked on the street) failures I have seen are output bearings.

So the first question is, is it full of oil?

They tend to whine before failure (see loss of oil).
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Old June 17th, 2013, 07:03 PM
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Quote:
Originally Posted by JSBriggs View Post
Ive see spline wear on the tranny output/tcase input result in the loss of drive. it appears as excessive drive train slop. The issue is with these trucks is what 'excessive' is can be hard to determine.

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Straight drive or auto?
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Old June 18th, 2013, 08:02 AM
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I think the input shaft wears pretty bad regardless of how well you take care of them. The consensus on the LT230 is that it will last a very long time if you keep fluid in it. Both of mine have a small amount of play in the front output shaft bearing, the Defender has been noisy since 37k.
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Old June 18th, 2013, 08:52 AM
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97 should have the cross drilled input, right? In any event, with the auto it is easy to replace the output on the trans and input on the LT230 if they do wear.
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Old June 18th, 2013, 10:48 AM
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Thanks for the input, gents. To answer evilfij, I've kept Mobil 1 75-90 synthetic in my t-case since i bought the truck at 65k. It now has 145k. I last changed the t-case oil 2k miles ago. It's full.

While it's been whiney for the last 30k miles, I have a new symptom which is quite perplexing. When I come to a form stop and then take off again, there is a bump in the drivetrain - usually 3-6 feet before and after the final stopping point.

This truck is my daily driver. I need it to be reliable. I'm trying to decide if *now* is the time to rebuild or replace the t-case. And if so... how/with what?
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Old June 18th, 2013, 10:51 AM
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What makes you think the bump is the Tcase?

Find a dirt road and try it with the diff lock on and see if it still does it.
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Old June 18th, 2013, 10:58 AM
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Quote:
Originally Posted by evilfij View Post
What makes you think the bump is the Tcase?
This is my 1st rodeo with an old t-case and I have no clue what else it could be. This is a process of elimination. The next thing I'll check is the DC rear drive shaft that never quite cured the pinion angle problem generated by the 1.5" life I gained with OME springs.

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Find a dirt road and try it with the diff lock on and see if it still does it.
Roger. Will try that at lunch.
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Old June 22nd, 2013, 07:22 PM
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Resolution!

Spline Bind. Rear shaft.
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  #10  
Old June 22nd, 2013, 10:26 PM
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Good to hear. Can you explain what spline bind is please?
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