LT95 front output clunk

[Elguru]

Hi Guys,


I,ve been having problems with “clunks” from front output shaft of my LT95.
It’s been driving me bloody batty as I have…

Rebuilt and reshimmed intermediate shaft.
Replaced centre diff and shims. Correct preload on shaft.
Front prop shaft checked and rebalanced by pro shop.
Replaced diff lock vacuum actuator.

Still I have 15 degrees of movement on front flange a distinctive clonk on back & forth rotation.

Removed the front output housing and moving the centre diff shaft all is perfectly snug, smooth, quiet and barely any backlash.

I have genuine new dog lock up sleeve but it looks exactly like the installed one.
The genuine manual implies the dog is installed the opposite way to the parts manual…. Which is correct.?

Any help and advice gratefully received.

Thanks Andrew

[Elguru]

Trying to post pics

[Elguru]

Again

[BEARMAN]

G'day Elguru. In answer to your photo question, that locking dog is on the incorrect way. The grooved end for the actuator fork should be facing forward. If you have a look at the internal teeth on the dog you will see the ones that engage the front shaft are actually tapered to hold it in position. So it would not be unlocking if installed like it is in your pic. That would probably explain the clunking especially when you back on or off throttle. Install it on the centre diff first and then bolt the front output housing on next. Like in the "Dad and Dave" stories - turn her over mate!!!!

[Elguru]

Thanks Bearman…..

I actually had two pictures of the dog installed but the one correct wouldn’t upload.
The the dog was installed the opposite “correct” way to the pic above…

Anyway I replaced the dog even though it was perfect and the operating fork which was quite badly worn. It’s definitely better now but still a bit clunky but I’m going to live with it…. I have had enough. 🙁

[Elguru]

Hi guys again……

So I replaced the diff lock dog & actuating fork which has helped a bit.

However I still have an unacceptable clonk when on & off the throttle. Definitely less so in low range. So I’ve removed the bloody transfer case cover again and trying to determine whats the cause.
Just to reiterate there is a new centre diff installed and the intermediate shaft has been shimmed to spec.
Is there anyone who has knowledge of the LT95 gearbox who could maybe do a “FaceTime” and have a live looksee at the operation and backlash etc of the gears etc…?

Thanks.

[BEARMAN]

Did you set the preload on the new centre diff when you installed it.