OK.

I just got the bad news.

The output shaft is stripped at the transfer case end as is the receiving gear.

So what are the options gents? ______________________________
Vogue tdv8 08MY poverty pack - wow

Sorry to hear that.

I guess it would depend on the availability of parts ‘down under’. The output shaft on the transmission isn’t difficult to swap out if you can get hold of one

Click image to enlarge

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thanks Phil for the prompt reply. An option nearby is a wrecked 10MY facelift L322.

One option is parts from the L322 facelift tranny and transfer box.

The 2nd option is a tranny rebuild by zf and buy the facelift transfer box.

The 3rd option is a zf tranny rebuild and transfer box repair.

which do you think are most viable?

thanks ______________________________
Vogue tdv8 08MY poverty pack - wow

Last edited by rar110 on 2nd Jul 2015 8:54pm. Edited 3 times in total

just trying to figure out what has happened here. the splines on the rear otput shaft and the splines on the corresponding tranfer box coupling have sheared/stripped. yes? possibly because no anti seize grease fitted? how would that coupling strip teeth whilst cruising? i could sort of understand if it was some huge power say in low range etc. has not something seized within the transfer and found a weak point to keep 'moving' like that coupling?
showing my colours here, but would not a secondhand (warranted) complete gearbox/transfer just be the ticket? i think you were on some decent milage on the car already.

I replaced my gearbox just last week due to various driveability issues, and upon removal, found the splines were very worn on both the gearbox output, and transfer box input.

I did have pictures of it someplace...

johnboyairey wrote:

the splines on the rear otput shaft and the splines on the corresponding tranfer box coupling have sheared/stripped. yes?

Another member here had his D4 box rebuilt by ZF Sydney for $4400. They are continuing with that same deal for a full transmission rebuild including output shaft. ZF told me most 6HP26s (most are from other makes) get to about 180,000km, although they have seen them get to 700,000. ZF advised that at 240,000 km the stator bush and TC are likely to be worn.

I also need at least a transfer box input gear. Although at 240,000 km other components like bearings, chain and clutch plates are likely to be worn. I might try to pick up a newer transfer box from a 10MY facelift wreck with a lot less km.

Can anyone confirm if a transfer box from a facelift L322 3.6v8 will fit ok? ______________________________
Vogue tdv8 08MY poverty pack - wow

I have a 2010 and my replacement transfer box came from an early 3.6 V8 so it certainly works backwards.

Thanks. What happened to your transfer box and what mileage? ______________________________
Vogue tdv8 08MY poverty pack - wow

It had an oil leak. Its a very long story and quite interesting. I have a couple of pictures. When I have time I will write it up!

I

RRPhil wrote:

Sorry to hear that.

I guess it would depend on the availability of parts ‘down under’. The output shaft on the transmission isn’t difficult to swap out if you can get hold of one

Click image to enlarge

Click image to enlarge

Previously-enjoyed DD295 transfer cases are relatively plentiful here in the UK because the same case is used in the Disco 3, Disco 4 and the RR Sport but I don’t know how easy they are to come by in Oz?

Having said that, if the parts are available then an input shaft swap ain’t difficult either

Click image to enlarge

Click image to enlarge

And in case you fancy having a go yourself :

http://www.fullfatrr.com/forum/topic14798.html

http://www.fullfatrr.com/forum/topic12404.html

Phil

G'day PHIL
Do you have ZF part numbers?
How hard is it to get the tranny out? Can it be done at home on a slab?

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated  ______________________________
Vogue tdv8 08MY poverty pack - wow

Phil
I looked at your 6hp26 pull down thread again. Swapping over an 10MY box other than the ECU looks doable. Other than the ECU, the box looks hydraulic/mechanical and should be identical. ______________________________
Vogue tdv8 08MY poverty pack - wow

I've bought another transmission & transfer box which fortunately has an identical ZF spec number of 1068 020 075. I found a ZF spec list that says all except very early 3.6 tdv8s had the same spec number. This is in contrast to D3/4s which listed lots of different ZF spec numbers. Many of the RRS tdv8s had a transmission with the same spec number. However, it wasn't used on any D3/4.

Here's a pic of the old transmission output shaft. Rust dust everywhere. It didn't shear the spline. The tips of the spline at both ends just rusted and wore away. RRPhil was on the money.

I spoke to the mechanic on Friday. There's not many L322s here, mainly D3/4s. So he hasn't done a L322 tranny swap before. As my L322 replacement box looks a lot less used and has the same parts list/manufacturers spec number as the old box, I'd like to fit the entire thing including the newer mechatronic. However, it sounds like the tranny ECU is VIN specific.

Can the new tranny mechatronic ECU be flashed/updated with my VIN or am I stuck with using the old mechatronic?

Here's a pic of the new tranny.

And the tumbleweed rolls past. ....

The old mechatronic will be fitted this week. ______________________________
Vogue tdv8 08MY poverty pack - wow