Gearbox Issue?

Just rebuilt the gearbox on my series 3 and noticed this when putting the transfer box back on. You can see the gears of the transfer box here, the high range gear only connects with half of the intermediate gear when the locking pin for 4WD is in its slot. This doesn't look right to me do I need to adjust it and do I need to take the front wheel drive cover off again? Got a feeling its not set up right inside I don't know if it was a runner when I got it as the synchro clutch had exploded so just rebuilt all that.
Everything turns smoothly .
Any thoughts?

You are right. That's wrong.


The square gear on the output shaft ( top right) is the low gear, permanently engaged on the splines of the shaft. The helical gear on the bottom of the picture, right, is the high gear.
When the square gear is at the bottom of the shaft it locks into the teeth at the base of the helical gear, making the helical gear the driver for the output shaft (driven by the the helical part of the intermediate cluster).


When the square gear is at the top, it's the driver for the output shaft, driven by the square gear on the intermediate cluster.

It should be fully in mesh, yours isn't right.

What's stopping the gear go the whole way up?

Is it the lever?

Wildefalcon said:

What's stopping the gear go the whole way up?

Is it the lever?

Click to expand...

Its when the locking pin for 4wd is pushed down into its slot that the gear doesn't fully engage.

EDIT. Hang on a minute if I'm looking at it wrong then the pin shouldn't be engaged when in low box anyway should it.....maybe I'll put the levers back on that way I'll know whats engaged and what isn't.

Yes, no, if you don't have the floor in place then make sure the yellow knob is fully up.
Then use the red lever only.
They interact.

ok thanks got it sorted, gearbox is on the bench so put the levers back on......I was pushing when should have been pulling lol.
I think its all working as it should, won't really know till I get the engine sorted.

That's the constant fear. Despite your best efforts it doesn't work, and you only find out when the project is finished!