Gearbox problem

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Steve Ashworth

Active Member
Posts
419
I have a series IIA
Runs OK in firsr and second gears, whan I change up to 3rd / 4th gears it whines really loud. Sounds more like I changed down a gear rather than up! Does not accelerate as you would expect.
Seems strange - any ideas?
Thanks
Steve
 
On inspection there is a shaft, about inch diamater that protrudes from back of gearbox a couple of inches.
I can push it back in with ease, I am no expert but I doubt if that should happen.
Is this a clue?
Steve
 
this is on the transfer box right? just above where the propshaft fits.if it is thats the shaft that governs whether you have selected high or low ratio.looks to me as if your linkage is broken and you may well be stuck in low.
 
Andy66,
I think you may be on to something there. There is a slot at the end of the shaft but no tab to secure it.
If I push the shaft in and fix a securing tab do you think it will be OK or will damage have been done whilst it has been loose?
Cheers,
Steve
 
I suspect damage will have been done.

The gear that runs on this shaft has caged roller bearings inside it that may well be breaking up or have broken up. There are also thrust washer between the gear and the transfer box casing.

Your best bet is to drain the transfer box and remove the bottom cover, about a dozen bolts. Be warned that there is a cork gasket behind the cover and it is easily damaged so expect to have to replace that. Anyway, once 'inside' you should be able to see and inspect the damage......actually you will get a pretty good idea from what comes out in the oil :)
 
Might be worth a look in tranfer case as Andy suggests, particlarly if shaft pushes in easily as it shows its still alingned correctly.

once bottom comes off and shaft pulled out you can inspect all the bits for wear

trhe pics show the little plate keeping shaft in (bolt removed)

and the intermediate shaft in the middle
 

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Thanks,
Unfortunately it looks like the gearbox will have to come out.
Is it possible to do this without ripping the inside out and taking it out the door?

Steve
 
Transfer box is rebuildable in situ, unless casing has been damaged by floating gears.

Gearbox has to up and out of the passenger door if you do not have removeable gearbox crossmember on the chassis. It will be a bolt in affair. If you are handy with a welder then this is the ideal oppotunity to make this 'adjustment' :)

Otherwise, removing the passenger door completely can give you just that little bit more room.

HTH
 
Thanks Andy,

I think I will be quicker cutting out the crossmember.

Will a 1981 series three gearbox be compatible as a swap out, I think the engine is already a series 3 but dont know age.

Cheers,
Steve
 
Last edited:
The S3 box clutch slave is in a different place (opposite side), so clutch release and actual clutch are different. If you get all those bit with the box and you can make a new pipe to from clutch master to slave (I don't think the old one will reach) then yes, pretty much a straight 'nut and bolt' swap.
 
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