Here is the history:
The clutch started to play up on my calibra, so i decided its time to replace it, and at the same time, lighten the flywheel and do a new cam! The tx box did trip out a couple of times in the past few months but the gearbox was sound and no problems.
But as you know to get the gearbox out, you have to take the tx box out! THat wasn't a problem, got the tx box, only the outer case inc all clutch plates and the big wheel in the middle of it out, and then dropped the gearbox out the side.
Coming back to refit the lot, geear box went in ok, but when doing the tx box, what a bitch of a job to get the clutch plates in! One of the clutch rings was a bit shaged, which could explain the fact that tx box tripped out a few times on me. When putting the clutch plates in, i noticed that there are two plane rings, i think gold in color, that you have to put on either side of the plates. One is quite thick and the other thin! We put the thin one in first, then rebuilt the clutch plates, and then finished off with the thick plate. SO the thick plate is closer to the rear diff and the thin plate at the front towards the engine.
Coming to refill the boxes, some ****** had cut the breather pipe off a bit short on top of me transfer box, so i removed the temp switch and filled it up with about 0.7l of dextronIII.
Going to refill the gearbox, the bolt was really tight and couldn't be undone, so removed the, i think reverse light switch, on the buttom of the gear box and refilled with 2l of Vx gear oil. But i forgot to remove the breather screw from top of the box when doing that.
Removed fuse 19, started the car up, all ok, no nasty noises or anything. Bled the 4x4 system, again everything went ok, no problems.
Put the fuse back in, did the whoosh test, all ok. Switch her on, the light went out, so i am thinking oh great. Its all working. Whilst on a two post ramp with the wheels off the road, put her in first gear and slowly release the clutch. I can hear this clunking noices from around the tx box area. But my mate, who is a mechanic and have been working on the car with me so far, said its coming from the gearbox not tx box! whilst in first gear, the front wheels are turning much faster than the rears! As soon as i dip the clutch in to change gear, i hear this big clunking noise again and then the whole rear diff locks up! but still no 4x4 light coming on showing me i have ***ked it up!
Switch off instantly, and then turn the wheels with hand, they all turn, turn the prop with hand, a bit hard to do, but no problem, the rears turn but not the fronts!
So i am baffled as what could have caused this! Any ideas? I will be stripping the tx box out again tomorrow and check the plates and inside the box to make sure everything still ok.
Any idas welcome