Roamerdrive noise

 I had to remove my Roamerdrive (overdrive) in order to get at the transfer-box so taht I could remove it too. I want to do some routine maintenance on the T Box. It's been on for 26 years and covered 170K miles. A few months ago, when the OD was last engaged, I thought I was starting to hear a noise and it's been in my mind to investigate. However I have continued to use the vehicle for local journeys.

Here is a video taken today straight after removing the unit. I am assuming horrible things are happening inside and I will need to open it up, hence this thread

Whilst I think about whether to do the LT230 overhaul / upgrade myself or ask Ashcroft Transmissions to send me an exchange unit, I cleared the bench and started to look into my Roamerdrive. The only problem that I have had with this was in the first few long miles with it engaged, driving through France. I had been unable to deselect it as it dropped into a 'neutral' position. I had needed to stop before it would engage. That was found to be a rose joint vibrating loose and lengthening the selector rod. The effect of that was to reduce the allowed travel between engage and disengage. Since then, it has behaved perfectly until recently it began to sound 'noisy'.

As I was removing the Transfer Box I had to remove the overdrive anyway and as soon as it was on the bench it was clear that something was amis, as featured in the clip posted above. I have started to dismantle it and pulled the front of the case to allow access. Almost straight away I began to find pieces of metal.

Three cap-head screws to release the front cover and can already see metal in the wrong place...

The rear housing with the sun shaft and caged needle bearing which locates in the planetary housing in the front section

Releasing the selector rod

Then the detent housing with spring and ball and the selector shaft with ring

This is one of the baulk rings which provides the synchromesh action. It is polished smooth when there should be fine grooves around the face

Lots of bits that shouldn't be there, and the synchro hub sliders, which should.

These sun shaft teeth engage with the three planet gears... oh dear, more damage is still to be unearthed.