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Transfer Case issues

L

LRZCP

In Second Gear
I have a 300 TDI Landrover and have been experiencing issues with the transfer case; there is a high pitch whine while driving the car (particularly noticeable in 4th and 5th gear) and the most worrisome symptom is the sign of metal filings in the transfer case (the gear oil was silver with tiny metal filings).

We sent down both the gearbox and transfer case to a reputable landrover mechanic (in Zambia) and he was unable to find any major issues; he noted a minor chip on a gear tooth but he mentioned seeing cars drive and function with much worse. Unfortunately, no diagnosis for the metal filings in transfer case.

We are currently, in the rainy season and attempting to over haul our vehicles for the upcoming field season. The Transfer case is still exhibiting the metal filings and high pitch whine (now prevalent from 3rd to 5th gear).

I was wondering if anyone could offer any insight or advice to tackle the issue.

Thank you for your help.
 
A tough one no doubt in your part of the world.
If oil is readily available I would drop it and remove the large inspection cover on the bottom of the case this would give you a first insight into any visible signs of damage.
The case itself is not difficult to split from the gearbox but is a heavy lump so plenty of blocks and trolley jack is best to remove it.
Without stating the obvious , something is misaligned or worn to cause this and I suspect the whining noise is the metal against metal . I would not really drive it , if that is at all possible otherwise it could cause a failure of the transfer box within time ,this normally happens as you'd expect at the worst time and place ! Sorry can't add anymore ,however there are hopefully some more tech minded chaps here that will follow up in time .
 
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