[crewsy]

My transfer case had 6.5's in it when I bought the car so I don't know how it was put together but here are the symptoms:

- it's very clunky when changing gears
- it whines loudly through 3rd, 4th and 5th gears
- ive got underneath and played with the drive shaft so I know it isn't the uni's
- looks like excessive movement/play between the gears (wrong backlash?)

Now I've come to the conclusion that maybe my shims aren't thick enough so the gears aren't meshing across the full face of the teeth, but I could be wrong.

If anyone has any knowledge on this please help!

[Teracis]

Mine whines at higher speeds (yes 3rd-5th) but it's not the gear it's the speed, so anything around 80-110 it's whining, I think that's just the gears.

The clunking, I've had the same thing (and still have it because I only replaced one uni) and i was the uni's in my tailshaft, it was getting really noisy and had a metallic clang before I changed the rear uni, I didn't do the one at the transfer end though and now that one's going

It's seriously like 1mm of movement that I had in the uni and when I changed it, noise gone.

[TryHard]

crewsy wrote:

My transfer case had 6.5's in it when I bought the car so I don't know how it was put together but here are the symptoms:

- it's very clunky when changing gears
- it whines loudly through 3rd, 4th and 5th gears
- ive got underneath and played with the drive shaft so I know it isn't the uni's
- looks like excessive movement/play between the gears (wrong backlash?)

Now I've come to the conclusion that maybe my shims aren't thick enough so the gears aren't meshing across the full face of the teeth, but I could be wrong.

If anyone has any knowledge on this please help!

let me drive ur car .. lol .. the 6.5s are whiney .. the clunking are u meaning changing gears in trasncase ya ?

i think u shouldnt worry to much 6.5s are nosiey and i even have problems sometimes changing the between 4wd and 2wd but i just force it and ignore it ... the way i look at is is change your oil put good oil in .. and just ignore the noises unless it gets real bad .. i didnt know u had a 6.5 case in ur car atm ? never herd u mention this before ?

[crewsy]

Teracis wrote:

Mine whines at higher speeds (yes 3rd-5th) but it's not the gear it's the speed, so anything around 80-110 it's whining, I think that's just the gears.

The clunking, I've had the same thing (and still have it because I only replaced one uni) and i was the uni's in my tailshaft, it was getting really noisy and had a metallic clang before I changed the rear uni, I didn't do the one at the transfer end though and now that one's going

It's seriously like 1mm of movement that I had in the uni and when I changed it, noise gone.

mine whines from 50kph and up. I did check my uni's and it seems like theres no play in them at all . I wonder if there's any other factors that could contributing to this?

[TryHard]

crewsy wrote:

Teracis wrote:

Mine whines at higher speeds (yes 3rd-5th) but it's not the gear it's the speed, so anything around 80-110 it's whining, I think that's just the gears.

The clunking, I've had the same thing (and still have it because I only replaced one uni) and i was the uni's in my tailshaft, it was getting really noisy and had a metallic clang before I changed the rear uni, I didn't do the one at the transfer end though and now that one's going

It's seriously like 1mm of movement that I had in the uni and when I changed it, noise gone.

mine whines from 50kph and up. I did check my uni's and it seems like theres no play in them at all . I wonder if there's any other factors that could contributing to this?

you talking about 2wd on the road loud whines ?. ... dont have that problem .. and would have no idea what causing it ..

[crewsy]

TryHard wrote:

crewsy wrote:

Teracis wrote:

Mine whines at higher speeds (yes 3rd-5th) but it's not the gear it's the speed, so anything around 80-110 it's whining, I think that's just the gears.

The clunking, I've had the same thing (and still have it because I only replaced one uni) and i was the uni's in my tailshaft, it was getting really noisy and had a metallic clang before I changed the rear uni, I didn't do the one at the transfer end though and now that one's going

It's seriously like 1mm of movement that I had in the uni and when I changed it, noise gone.

mine whines from 50kph and up. I did check my uni's and it seems like theres no play in them at all . I wonder if there's any other factors that could contributing to this?

you talking about 2wd on the road loud whines ?. ... dont have that problem .. and would have no idea what causing it ..

Spose it's not really the whine that is bothering me. It's the extreme clunkyness of it.

[Teracis]

I have a whine in 2wd, it's not ear shatteringly loud, you have to know what you're listening for, the bloody engine and tyre noise is louder.

As for clunkyness, is that in 2wd or 4wd? Can you swap shafts with another zook to test if that's the problem?

Other idea if it's in 2wd, take the rear shaft out, lock the hubs, put it in 4wd and go for a spin (so it's FWD since you're rear shaft is out) and see if it still clunks.

If it's to do with changing from hi to low or 2-4 then ignore me.

[TryHard]

Teracis wrote:

I have a whine in 2wd, it's not ear shatteringly loud, you have to know what you're listening for, the bloody engine and tyre noise is louder.

As for clunkyness, is that in 2wd or 4wd? Can you swap shafts with another zook to test if that's the problem?

Other idea if it's in 2wd, take the rear shaft out, lock the hubs, put it in 4wd and go for a spin (so it's FWD since you're rear shaft is out) and see if it still clunks.

If it's to do with changing from hi to low or 2-4 then ignore me.

i think this is good idea will rule out rear diff

[crewsy]

Teracis wrote:

I have a whine in 2wd, it's not ear shatteringly loud, you have to know what you're listening for, the bloody engine and tyre noise is louder.

As for clunkyness, is that in 2wd or 4wd? Can you swap shafts with another zook to test if that's the problem?

Other idea if it's in 2wd, take the rear shaft out, lock the hubs, put it in 4wd and go for a spin (so it's FWD since you're rear shaft is out) and see if it still clunks.

If it's to do with changing from hi to low or 2-4 then ignore me.

Thats a good idea mate, I'll give that a go. It's a lot worse in 2wd than when I put it into 4wd probably coz the load is getting spread between both front and rear shafts so this will probably confirm it.

[Teracis]

TryHard wrote:

Teracis wrote:

I have a whine in 2wd, it's not ear shatteringly loud, you have to know what you're listening for, the bloody engine and tyre noise is louder.

As for clunkyness, is that in 2wd or 4wd? Can you swap shafts with another zook to test if that's the problem?

Other idea if it's in 2wd, take the rear shaft out, lock the hubs, put it in 4wd and go for a spin (so it's FWD since you're rear shaft is out) and see if it still clunks.

If it's to do with changing from hi to low or 2-4 then ignore me.

i think this is good idea will rule out rear diff

No it will only rule out the rear drive shaft.

I did basically the same thing with my zook but the problem I have is the front shaft, so I did exactly what I've posted but removed the front shaft and it was all good.

Basically I need a new uni in the transfer end of the rear shaft, and a completely new front shaft.

I reckon the OP needs new uni's in the rear shaft, or if he's unlucky it will be slop in the spline in the rear shaft and he's up for a whole shaft.

If the noise is still present then we move onto the rear diff, which will require jacking up, sambo has this problem iirc

[foolsp33d]

im just going to lob this here....

Video is of the input shaft on the 1.0 transfer I was running.. obviously making some horrid noises.. box out and this was the cause....
Yes.. my box is VERY grubby!!

http://www.youtube.com/watch?v=qzL9EWTLml4

[Teracis]

Holy crap that's a lot of movement!