Some History...
While on a recent trip to the Kimberleys I experienced a loud crunching noise come from the front end. Upon inspection I initially thought I had done the LH inner CV. After some thought and further inspection I found the problem to be in the Shift on the Fly Box. Removing the filler plug I found no oil - completely dry - my own fault...I knew about this box and knew it didn't receive attention during servicing by mechanic (does not get listed in the servicing schedule until 100k - mine had 85k before trip) but didn't give it a second thought during pre trip service (too many other things going on!).
Upon further inspection by removing actuator cover I found what I suspected - collapsed needle bearing in box. By now the axle has been flogging around a bit and the outer bearing and seal have flogged out allowing water into the box. Not having free wheeling hubs meant it would not be easy stopping this axle from spinning and hence causing potentially more problems...I still had 10k of travel before getting home. I could manage not having 4WD but wanted to prevent more problems.
The solution - Remove the drive hub from the LH side and file out the spline (30 minutes with a sharp file). Disconnect the power from the actuator on the box. I now had a free wheeling hub meaning the axle was no longer being turned by the wheel. I could now select low range (if needed) knowing there would be no drive to the box. If need be I could activate my front air locker giving me drive to atleast the RH wheel and still not turning the box over (turns out I didn't need this function - fortunately!)
So now back at home its time to fix it. Has anyone removed the Shift on the fly box before. I have the full workshop manual and am a fitter by trade so am comfortable doing the work myself - would have followed my nose in the bush if need be but fortunately that wasn't necessary. Until I get the box apart I don't know if the bearing and seals will be off the shelf jobbies or weather Isuzu will be called upon (hopefully not the latter) - numerous other options also but am keen to recondition this unit.
Anyone had this box out / worked on it before...your thoughts would be appreciated - thanks.
While on a recent trip to the Kimberleys I experienced a loud crunching noise come from the front end. Upon inspection I initially thought I had done the LH inner CV. After some thought and further inspection I found the problem to be in the Shift on the Fly Box. Removing the filler plug I found no oil - completely dry - my own fault...I knew about this box and knew it didn't receive attention during servicing by mechanic (does not get listed in the servicing schedule until 100k - mine had 85k before trip) but didn't give it a second thought during pre trip service (too many other things going on!).
Upon further inspection by removing actuator cover I found what I suspected - collapsed needle bearing in box. By now the axle has been flogging around a bit and the outer bearing and seal have flogged out allowing water into the box. Not having free wheeling hubs meant it would not be easy stopping this axle from spinning and hence causing potentially more problems...I still had 10k of travel before getting home. I could manage not having 4WD but wanted to prevent more problems.
The solution - Remove the drive hub from the LH side and file out the spline (30 minutes with a sharp file). Disconnect the power from the actuator on the box. I now had a free wheeling hub meaning the axle was no longer being turned by the wheel. I could now select low range (if needed) knowing there would be no drive to the box. If need be I could activate my front air locker giving me drive to atleast the RH wheel and still not turning the box over (turns out I didn't need this function - fortunately!)
So now back at home its time to fix it. Has anyone removed the Shift on the fly box before. I have the full workshop manual and am a fitter by trade so am comfortable doing the work myself - would have followed my nose in the bush if need be but fortunately that wasn't necessary. Until I get the box apart I don't know if the bearing and seals will be off the shelf jobbies or weather Isuzu will be called upon (hopefully not the latter) - numerous other options also but am keen to recondition this unit.
Anyone had this box out / worked on it before...your thoughts would be appreciated - thanks.
