[Scales]

As some of you may have known, i have rebuilt my WT case that i have fitted into my Jimny with new bearings, countershaft, shims, seals etc.

I got it all fitted up this arvo and took her for a spin, but getting a sort of gear lash noise as i go on and off the throttle, as well as a HIDEOUS noise when i put my foot on the clutch.

Heres a video so you can hear for yourself, the clutch action is towards the end of the clip. This was taken around 60kmh





Any ideas of what that noise is? and should i just accept it as normal? or have i got issues? I was kinda worried my output bearing on the gearbox was shagged.

[want33s]

Did you put oil in it?

[Fatzook]

WOW!!! Sounds bone dry!!

[Scales]

yep all oiled up, this is similar to the noise i heard before i rebuilt

[abclarke]

Fuck me that doesnt sound good! Id go with everyone else. Sounds dry as!

[Scales]

well, once again.... has oil in it.... VMX80. I just put it together, so i can guarantee! i put oil in it.

Like i said before too, it sounds the same as the noise before.

[Fatzook]

So you had this noise before the rebuild? Was the sierra case fitted then? Have you changed the uni's in the WT jack shaft?

[Scales]

yes the same case, the noise was the reason for the build. kinda shitted that i spent bulk cash and nothing huge has changed. the bearings sound smoother at least.

No i didnt touch the UJ's they seemed fine to me, but im no expert on UJ's. Do you think it could be coming from the Jackshaft UJ?

I thought it sounded like slop in the gears, and i can kinda feel a bit of give between the input and output shafts when i twist em by hand.

[Fatzook]

Scales wrote:

yes the same case, the noise was the reason for the build. kinda shitted that i spent bulk cash and nothing huge has changed. the bearings sound smoother at least.

No i didnt touch the UJ's they seemed fine to me, but im no expert on UJ's.

I thought it sounded like slop in the gears, and i can kinda feel a bit of give between the input and output shafts when i twist em by hand.

There will always be some movement/ slack. U-joints can make a very similar noise to worn bearings. For $50 and some tim, you can swap out the uni's. Or borrow a known good one off a WT and see if that makes a difference.

Perhaps you could even borrow a quiet transfer from somone to further the process of elimination?

[Scales]

no one in townsville to do said swap.

usually wouldnt mind shelling 50, but its cost me nearly a grand already for this swap.... so would rather be more conclusive.

would the UJ on the jackshaft exhibit the same noise with an equalisation of power? IE. Foot on the clutch.

Is there a way to test the UJ? or is it just suck it n see?

[Scales]

Heres some pics of the rebuild too so you can see the gears, and the new breather i threaded in.

[abclarke]

Scales wrote:

would the UJ on the jackshaft exhibit the same noise with an equalisation of power? IE. Foot on the clutch.

Is there a way to test the UJ? or is it just suck it n see?

Same noise come and go when its in gear and you press on and off the accelerator at speed?

[JrZook]

Countershaft thrust washers didn't get dislodged upon assembly by any chance?

[Scales]

yep, if i do it really slow, itll come up, then when the engine starts driving to the wheels itll go away, same on decelleration.

Pretty sure the brass washers stuck to the walls ok. i shook the housing about whilst it was off and the grease held them in place quite well.


Given the volume of the noise, im starting to think the UJ on the jackshaft might be pretty plausable. but theres no slack in them when i tested off the car. Can the internal bearings on them shag out and make that noise without making any slack??

[Scales]

Just thought of something then,
Will the UJ's off my old Jimny Jackshaft fit into the new WT jackshaft?? i can just swap em out tomorrow to test if thats the case.

EDIT
just looked at the old jackshaft, the UJ's are held in by some weird sort of crimping action, no clips to be seen... WTF?

[abclarke]

Scales wrote:

yep, if i do it really slow, itll come up, then when the engine starts driving to the wheels itll go away, same on decelleration.

My uni that was rooted on the jackshaft had a fuck load of play so youd see it if you had a play with them all.

But my noise was like a clunking when i accelerated quick or took my foot off the pedal quick.

[mrw82]

Not sure. But you could pull your WT uni's apart to inspect/grease them.

You'd be spewin to have spent a grand rebuilding a transfer case, only to find the problem is a $40 Uni joint

[Scales]

mrw82 wrote:

Not sure. But you could pull your WT uni's apart to inspect/grease them.

You'd be spewin to have spent a grand rebuilding a transfer case, only to find the problem is a $40 Uni joint

yeah thanks for reminding me.
wasnt a grand rebuilding, more like 600 when you take into account the gear i had to buy as well as the kit.
but the whole case swap was easily a grand.


How do you re-grease/inspect the WT UJ's? i thought they were one-shot's

Ive only got tomorrow to do the job before i have to go back to work for another 2 weeks, so would rather knock this on the head now so i dont have to sit and think about it for 2 weeks.

[abclarke]

Depending on the brand uni, some have a grease nipple?

[mrw82]

You can pump grease in via the grease nipple. But I tend to find it squirts past the seal of one or 2 cups and the others don't get fresh grease.
Pull the uni apart in the same method as you would to replace it (but be more careful), punch some grease into the needle rollers of each cup and reassemble.
If your uni joint doesn't have a grease nipple then its more then likely original and you should spend the money on new ones as they're likely stuffed

[boostedbrick]

Have you tried it with the jack shaft removed? Will rule out the gearbox if there is no noise, just run a drip tray under it. If the noise comes back once the shaft is reinstalled that's the problem.. Is the dust shield on the GB end of the shaft secure?

[Scales]

they dont have nipples, so i guess its a pull-apart job.

Any idea if that UJ i posted a pic of before will do the job? i cant see a clip on it anywhere, do they just get pressed through? Id like to try them if i cant re-grease the WT ones.

I ordered a set of greasables just then from ebay. why stop spending now?

I still want to make sure this is the problem before i leave for work, nothing i hate more than thinking about shit like that for weeks until i get home again.

[atari4x4]

that uni joint on the jimny shaft is staked... non serviceable unless it's only on 1 side of each yoke

[Scales]

dang it, Cheers dude. never seen that shit before.

I guess ill drop the WT jackshaft back out and press the UJ out and have a squizz, cant hurt now i guess.
Does one side of the UJ just pop off? never done em before, seen a few youtube vids but.

[atari4x4]

it's pretty straight forward, i use this technique



make sure you mark driveshaft so it goes back together the same way. mark the slip joint & either end of the driveshaft & the flanges/yokes.

this is the other way, but be careful not to butcher the shaft with the grinder http://www.auszookers.com/forum/viewtop ... it=uni%27s

[Scales]

Lol, that was the vid i watched atari. (i searched 1st)

so they are the same technique with the end cups popping off i take it?
I have a press btw.

[Brenno]

boostedbrick wrote:

Have you tried it with the jack shaft removed? Will rule out the gearbox if there is no noise, just run a drip tray under it. If the noise comes back once the shaft is reinstalled that's the problem.. Is the dust shield on the GB end of the shaft secure?

While you have your jackshaft out and before you pull your uni joints apart do this. BTW, new uni joints are around $20 each depending where you go.

[Scales]

yeah i did that when it was out the 1st time i think. pretty sure its not coming from there. but i will do it anyway to cross it off.

i got the 2 UJ's from 4wd Products on ebay for 50 beans delivered.


my plan tomorrow at this stage is,

drop jackshaft, press out UJ's carefully and check grease etc. May swap out with one of the rear shaft UJ's if i cant tell any damage.

while out, check gearbox without any shaft fitted.

I really hope i find something wrong. i hate not knowing what shit is wrong.

[want33s]

Oil in the GEARBOX?

[Scales]

yep oil there too

Ive got the jackshaft out now, and ive pressed one side of the UJ as far as it can go, but i cant seem to get the end cap off? any ideas?