Diesel rattle below the transfer case lever at 1800ish rpm

[Murray]

has anyone solved the odd rattle coming from below the transfer case lever adjustment knob. It's not the linkage to the cable and the collar still has the split pin. Any accelerations at low speed around 1800rpm seem to cause this rattle/buzz. Dealer has tried a few things. I have requested access to the technical documents to see the schematics! Bottle of red to anyone that can solve it !

 

[Happyoldgit]

Have you had hands on the transfer cable linkages to check their locknuts are tight and that the lever balljoints are still good and tight? Access via the transmission tunnel side panel and down from the top by removing the gaiter surround and pulling the gaiter up. Also worth checking the lever housing securing bolts are tight too.

 

[Murray]

I have had that apart a few times now to that level, it's bugging me so much I am going to dismantle to the next level now. there was. recall the transfer case before I collected the car and I worry the dealer has fitted incorrectly somehow. It works fine but if someone said they had dropped a screw I would believe them!

 

[Clark Kent]

Up your offer to a gallon of diesel and I think you'll get some buy-in Murray.
I mean a proper UK gallon too. Not one of those shortchanged US gallon things

 

[Murray]

haha one gallon of liquid gold

 

[Happyoldgit]

haha one gallon of liquid gold

Eyes and hands on the shift cables and other odds and sods from underneath the vehicle? Heatshields, brackets and whatnot.

 

[Eric.S.]

I’ve had the same rattling noise for about 45,000 km. It’s caused by the ball joints on the lever. As soon as I lightly rest my hand on it, the noise stops. I’ve checked everything and tried fixing it, but like I said, in my case it’s the small joints on the cables.

 

[Clark Kent]

Exploring @Eric.S. input for a moment, @Murray you could try adding or subtracting one turn from each or both cable rod end ball joints to see it that tightens up the cable runs and adds some preload to the hi-lo shifter. If it's the shifter that is rattling that might give it some hush.
Adjusting the cable will slightly alter the engagement but you can adjust then test to ensure that hi-lo and CDL lock-unlock are still selecting correctly.
I posted the steps to adjust the cables here.

Post in thread 'Low range will not engage after transfer case selector replacement' https://www.theineosforum.com/threa...selector-replacement.12421442/post-1333385966

 

[Murray]

Exploring @Eric.S. input for a moment, @Murray you could try adding or subtracting one turn from each or both cable rod end ball joints to see it that tightens up the cable runs and adds some preload to the hi-lo shifter. If it's the shifter that is rattling that might give it some hush.
Adjusting the cable will slightly alter the engagement but you can adjust then test to ensure that hi-lo and CDL lock-unlock are still selecting correctly.
I posted the steps to adjust the cables here.

Post in thread 'Low range will not engage after transfer case selector replacement' https://www.theineosforum.com/threa...selector-replacement.12421442/post-1333385966

Thats cracking thanks, my Saturday afternoon job then !

 

[Happyoldgit]

Just as I said, it may be the ball joints but always worth checking the cable locknuts but if you adjust the joints a tad you will be releasing and re-tightening them anyway. Spraying some white grease into the lever ballpoint itself wouldn’t go amiss either.