Think we may have sorted the leak out!!!

Got Hunters to swap the hi low pos switch over because rave says it needs calibrating, otherwise it is only held on with 2 bolts.

The o ring on the old one had perished and started to pull apart, leaving a small hole for oil to weep through! New one and new seal in so all should be good now! Fingers crossed!

http://www.fullfatrr.com/gallery/albums/us...G_2991.JPG There is nothing that can't be fixed with a hammer😜😜
FFRR 4.4 SDV8 Autobiography Santorini Black.
KIA E-Niro 4+
2010 LR D4 Commercial 2.7 TDV6

Last edited by northernmonkeyjones on 1st Oct 2014 3:25pm. Edited 1 time in total

Well my saga goes on and on.

Seems to have solved the oil leak, but I have a message on the dash saying that Hi Lo range out of calibration - It drives fine but it seems to be stuck in high range???? I've left it with a local guy that seems to think he can sort it??

You need to re calibrate the high low position sensor I reckon, needs to be plugged in at the dealer to be reset. Needs to be told what is high and what is low. There is nothing that can't be fixed with a hammer😜😜
FFRR 4.4 SDV8 Autobiography Santorini Black.
KIA E-Niro 4+
2010 LR D4 Commercial 2.7 TDV6

Had a check of the trans box while I was fitting my side tubes today. All seems dry so far! Will keep an eye on it over the next few months. There is nothing that can't be fixed with a hammer😜😜
FFRR 4.4 SDV8 Autobiography Santorini Black.
KIA E-Niro 4+
2010 LR D4 Commercial 2.7 TDV6

Hi all.

I'm new on here and please don't flame me for owning a Disco/LR3 HSE UK spec!

I have found this thread after just having a 48 hour battle rebuilding the Steyr transfer box. Mine appears to be bearings close to failure. In any event on reinstalling the box it all fired up okay and then there was a metallic clunk and warning messages D186 Clutch actuator stuck and therefore no range hi-low range control. It will either do this on startup or as soon as drive is engaged. We've stripped the box about three times and cannot see anything we are doing wrong. I also had the luxury of a second box that I opened and did a side by side comparison on the bench. This determined every component was located or orientated in its correct position.

Is this a simple case of calibration or is it something more serious I've done wrong in the rebuild ?? 😬. I want to get it working as I've already bought and installed new seals/bearings/chain and an oil pump.

Both boxes have been in my car and apart from the rebuild had worked prior to strip down.

Any help gratefully received.

Thx

Tony

I think, and don't quote me on this that it may need plugging in to reset stuff when you swap or reinstall components.

Either that or there is a problem with the clutch solenoid, if you have another box I would be tempted to swap that over and see if it makes a difference. There is nothing that can't be fixed with a hammer😜😜
FFRR 4.4 SDV8 Autobiography Santorini Black.
KIA E-Niro 4+
2010 LR D4 Commercial 2.7 TDV6

Many thanks.

I have a Bearmach Hawkeye v7.00 but it doesn't do recalibration (I may complain to them !! ). I know Nanocom and IID do but I could do without buying another one for the moment. I'll see if that works then look at changing the solenoid although I am pretty sure it's working (unless some thing mechanical has broken it post-rebuild.😬

The strip down guide by RRPhil is excellent. Pity I didn't have it before I started the strip down but you learn as you go!!!

I had exactly the same problem with mine after re-build. It would not calibrate. I tried to reset it via a manual method (which I will try and find for you) and with a mates diagnostic tool which was quite advanced?
I ended up buying a second hand box with the actuators fitted and replaced the whole thing and everything was fine. After I fitted the second hand box I didn't have to callibrate or do anything - it just worked fine!

I still have the reconditioned box, but too scared to sell it in case its not working correctly.

One thing I do remember from the actuator is that it had printed on a label on it; - If Dropped - Scrap! It was a Bosch unit and I still have it somewhere if you want to borrow it.

I have the same thing written on mine. Luckily I bought a spare transfer box so I could still operate whilst a refurbished my original. Sadly the chain is stretched in that but it does mean I have pretty much 2 of everything. I have seen some instructions for a manual calibration pressing the brake pedal and pressing he selector switch etc but it did t seem to do anything on my car.

I have a mechanic with kit that can do the calibration so it's booked in for that tomorrow. We shall see! If your manual calibration is a different way, I'm happy to try it. 😊

I will try and find it. I printed off from a website somewhere!

Phew,!

All sorted.
Recalibration with an Autologic in 2 minutes flat..

Lesson learned. Don't doubt your own spanner work !

Thx

Tony

👍 had a feeling that would be it. There is nothing that can't be fixed with a hammer😜😜
FFRR 4.4 SDV8 Autobiography Santorini Black.
KIA E-Niro 4+
2010 LR D4 Commercial 2.7 TDV6

Hi, I've just found this fantastic tear down thread.
We replaced our transfer box in a 2008 TDV8 FFRR with a secondhand one, it now bangs and clunks a low speed when turning left or right and the wheels feel like they are grabbing. Will recalibration with Autologic or similar fix or does this mean the secondhand one is useless?

No errors on dash and it moves from high to low ok. Thanks

doesn't sound like a calibration issue to me. Not sure what is causing that, it could be a stretched chain in the box, Have you checked the CV joints, I wouldnt think that a transfer box problem would only be present when turning, I'm not sure that that would make a difference.

However if the CV joints are wearing then you would get a knocking when turning. It may be front driveshaft related? There is nothing that can't be fixed with a hammer😜😜
FFRR 4.4 SDV8 Autobiography Santorini Black.
KIA E-Niro 4+
2010 LR D4 Commercial 2.7 TDV6

Hi thanks northern monkey.

The set up was perfect prior to installing this replacement transfer box just a bearing noise no clunking. Now with the unknown replacement there is clunking and banging coming from the box and the wheels are grabbing like something is locking up.

I'll keep going and post the answer here once I find it 2015 SDV8 AB
2008 TDV8 Vogue gone
2005 TD6 Vogue gone
2003 TD6 Vogue gone