80 series unknown drive line issue

Submitted: Friday, Jul 31, 2020 at 10:16
ThreadID: 140304 Views:875 Replies:6 FollowUps:8
Hi Guys,

I'm looking for some help to see if anyone has run into the problem I'm currently having with my manual 96 DX 80 series.

So what kicked it off was trying to take off at a set of lights on a hill,

As I released the clutch I started moving but then once I started to accelerate more a loud clunk and shudder went through the vehicle and lost drive forward. I tried again, the same thing but managed to feather the clutch to get enough drive to get around the corner.

Now on the flat, I tried to get going again and this is what I think I have found.

I can get take off, get up to speed and change gears ok (all the way up to 4th), the problem starts when I accelerate and put too much torque through the car. this is when the massive clunk sound happens and I lose power (power moving forward the engine is fine).

This also happens in reverse.

So my question is what is it that could be causing the problem? gearbox, transfer case, rear dif?

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Reply By: RMD - Friday, Jul 31, 2020 at 11:32

Friday, Jul 31, 2020 at 11:32
Seeing it happens under high torque situations, have you checked the transfer case lever isn't being pushed to neutral by the boot being hard rubber and or mud and crud underneath flicking it out of drive when the whole box and TC rotates to the right under load? If the stick is being affected it can simply return to drive when load is taken away.

Rear gearbox mount ok is it? Engine mounts too? If not healthy that will increase the problem.
AnswerID: 632770

Follow Up By: Mark 80 - Friday, Jul 31, 2020 at 11:37

Friday, Jul 31, 2020 at 11:37
Awesome, ill have a look into it this afternoon, thanks for the suggestion.

When I say high torque, it's pretty much anything above light acceleration...
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FollowupID: 909650

Follow Up By: RMD - Friday, Jul 31, 2020 at 13:48

Friday, Jul 31, 2020 at 13:48
Could possibly be the clutch plate centre broken and only grabbing/driving under low torque. It would make a fair thrashing noise if happening.
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FollowupID: 909652

Reply By: Nomadic Navara - Friday, Jul 31, 2020 at 12:57

Friday, Jul 31, 2020 at 12:57
How is the cardan joint?
PeterD
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AnswerID: 632772

Follow Up By: RMD - Friday, Jul 31, 2020 at 13:44

Friday, Jul 31, 2020 at 13:44
Not sure how a cardan joint can disconnect drive and then reconnect again, and also do it in reverse. Break once perhaps!
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FollowupID: 909651

Reply By: Member - McLaren3030 - Friday, Jul 31, 2020 at 13:05

Friday, Jul 31, 2020 at 13:05
Hi Mark,

Have you asked this question on the Landcruiser Owners On Line (LCOOL) forum? It is a forum with sections for each series of Landcruiser. You may get an answer there.

Macca.
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AnswerID: 632773

Reply By: axle - Friday, Jul 31, 2020 at 15:03

Friday, Jul 31, 2020 at 15:03
If not whats mentioned

Transfer case input gear/shaft wear.

Good luck

Cheers.
AnswerID: 632776

Follow Up By: RMD - Friday, Jul 31, 2020 at 16:05

Friday, Jul 31, 2020 at 16:05
Axle
Does that mean the shaft has worn/moved to allow the gear teeth to jump? If shaft worn to that extent it would have been making a fair amount of noise which would have been evident when driven. Just bearings not so good causes a loud noise while driven. Maybe the change ring and associated selector moving away from High position, a bit like the lever being moved causing the same symptoms.
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FollowupID: 909653

Follow Up By: axle - Friday, Jul 31, 2020 at 18:01

Friday, Jul 31, 2020 at 18:01
RMD,

I'm thinking internal wear in the gear making it jump on the shaft splines under load if the lot is worn But it would have to have done a lot of work. Who knows , hope it the simpler things for his sake ... lol


Cheers.
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FollowupID: 909657

Follow Up By: RMD - Friday, Jul 31, 2020 at 19:08

Friday, Jul 31, 2020 at 19:08
Axle.
I see what you mean. From what I can see in my very similar 60 series diagrams the dogs on the dog clutch/ring may be worn. That would be felt in the transfer lever when it happens.
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FollowupID: 909661

Follow Up By: Bob Y. - Qld - Friday, Jul 31, 2020 at 19:46

Friday, Jul 31, 2020 at 19:46
Tha DX models, from what I recall, had the standard transfer case, as fitted to the 79 series utes & 78 series troopies. The large nut on the t/c input shaft, that holds the dual gear sets tight, would rarely be retightened, so the gear sets move about on the splines, promoting wear. All as Axle suggested!

From the few examples I’ve seen, it’s either go or not. Haven’t heard of spasmodic movement with this fault. Maybe the gear set is moving enough to gain some momentum?

Bob

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Can't remember most of it.

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FollowupID: 909668

Reply By: Oscar H - Friday, Jul 31, 2020 at 17:55

Friday, Jul 31, 2020 at 17:55
Hi,
Had a simular thing on a 92 with free wheeling hubs. Thought it was gear box or clutch.
Turned out to be drive dog collar on front wheel with some teeth missing.
John.
AnswerID: 632781

Follow Up By: RMD - Friday, Jul 31, 2020 at 19:04

Friday, Jul 31, 2020 at 19:04
If Mark's 80 is a constant 4wd model then that is another viable possibility, but only if his has been fitted with FW hubs instead of drive plates.
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FollowupID: 909660

Reply By: Member - Barnray (NSW) - Friday, Jul 31, 2020 at 20:02

Friday, Jul 31, 2020 at 20:02
There is a possibilty that the drive spline between the gearbox and transfer box is badly worn. Mate lost drive in his Crusier with a worn out spline, had to rebuild the gearbox. R
ps it is a known fault.
AnswerID: 632783

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