How do I separate the transfer box from the gearbox?

RoyRover · Jun 28, 2014

Dear Forum,

Please could a forum member advise how to remove the transfer box before removing the gearbox on an oldish Defender (split windscreen)?

I have removed the propshafts, mountings and all the bolts surrounding the transfer box, but it still appears firmly attached to the gearbox?

Does (perhaps) the L/H mounting plate bolt to both the transfer box and the gearbox, thus holding them together?

Thank you.

Dr_evil · Jun 28, 2014

first off do an intro in the proper section

jamesmartin · Jun 28, 2014

RoyRover said:
Dear Forum,

Please could a forum member advise how to remove the transfer box before removing the gearbox on an oldish Defender (split windscreen)?

I have removed the propshafts, mountings and all the bolts surrounding the transfer box, but it still appears firmly attached to the gearbox?

Does (perhaps) the L/H mounting plate bolt to both the transfer box and the gearbox, thus holding them together?

Thank you.

defenders dont have split screens,does box have 4 or 5 gears ?

Dr_evil · Jun 28, 2014

jamesmartin said:
defenders dont have split screens,does box have 4 or 5 gears ?

They do if they're ringers

jamesmartin · Jun 28, 2014

Dr_evil said:
They do if they're ringers

ffs theres plenty of legit hybrids just as theres plenty of nicked standard vehicles,and coming from someone who was building an abortion its a bit rich

Freelaner · Jun 28, 2014

Dr_evil said:
They do if they're ringers

it's not beyond the realms of fantasy that one has been retrofitted either

fanatic · Jun 28, 2014

jamesmartin said:
ffs theres plenty of legit hybrids just as theres plenty of nicked standard vehicles,and coming from someone who was building an abortion its a bit rich

Pmsl.

Dr_evil · Jun 28, 2014

jamesmartin said:
ffs theres plenty of legit hybrids just as theres plenty of nicked standard vehicles,and coming from someone who was building an abortion its a bit rich

Oooh touchy aren't we

something crawled up your arse and died ?

jamesmartin · Jun 28, 2014

Dr_evil said:
Oooh touchy aren't we something crawled up your arse and died ?

just pointing out a few facts,are you an only child

Dr_evil · Jun 28, 2014

Nope, but you are being touchy

something's definitely pushed a button. Could it be the lack of immigrant threads recently ?

jamesmartin · Jun 28, 2014

Dr_evil said:
Nope, but you are being touchy something's definitely pushed a button. Could it be the lack of immigrant threads recently ?

dont be a prick

RoyRover · Jun 29, 2014

jamesmartin said:
defenders dont have split screens,does box have 4 or 5 gears ?

Hello Jamesmartin, thanks for your reply.

I am not a Land Rover expert - Owned a series 1 Disco for a few years and have driven Defenders both in the RN and here in Cyprus. I actually own a 1973 Rover P6 2200 which I have restored (I thought it might be impolite to ask a Land Rover question on my Classic Rover forum!). A friend, knowing how much time I spend covered in oil has asked me to help him refurbish the gearbox on his Land Rover...Hence my question to your forum.

Jamesmartin, as you point out, this Landy may not be a Defender; maybe a series 3? I will post a pic tomorrow (it might help)?

jamesmartin · Jun 29, 2014

a picture of the boxwould help to ,if its a 4 speed t/box wont unbolt until you drop sump and remove the large shaft and drop intermediate gear ,there are 3 bolts on the outside and 3 nuts inside t/box, if its a 5 speed there are 6 external bolts or nuts only 2 from the front back on rhs and 4 back forwards on lhs, it would take a lever to start splitting boxes,and if input gear and mainshaft splines are worn can be very hard to split as splines can wedge together,in which case removing pto cover and whacking main shaft end whilst box is levered would help

RoyRover · Jul 3, 2014

Hello Jamesmartin,

It is now obvious to me that this is a Series 3; should I try posting on the 3-series website?

Here is a pic of the Land Rover:

And here are pics of the transfer/gearbox:

Since taking these pics I been online for a schematic (I think it is the correct one) and have removed the transfer box sump and one of the bolts inside it etc, but I appear unable to get the intermediate gear shaft? to withdraw fully in order to get at the others?

Any ideas, please?

jamesmartin · Jul 3, 2014

intermediate shafts can seize in tight where shaft touches outrt case but if youve got it moving it should pull out easily once hand brake assembly is removed

RoyRover · Jul 3, 2014

jamesmartin said:
intermediate shafts can seize in tight where shaft touches outrt case but if youve got it moving it should pull out easily once hand brake assembly is removed

Thank you for your patience, jamesmartin.

Everything is removed and the intermediate shaft pulls out easily for practically its entire length - Then it seizes up and will not come out completely.

We have even tried to drift it out with a cold chisel in the slot at its outer end (the slot for the locking plate) to no avail.

It almost feels like there is some sort of locking mechanism on its inboard end?

jamesmartin · Jul 3, 2014

theres is nothing , its possible shafts got a groove worn in through failing bearing

RoyRover · Jul 16, 2014

jamesmartin said:
theres is nothing , its possible shafts got a groove worn in through failing bearing

Hello Jamesmartin,

You were spot-on above!

By way of a small thank you for your kind help, I will post here some pics showing how we eventually got the shaft out and the damage that had prevented its easy removal, just in case this should ever prove useful to one of your forum members in future!!

We welded an 'eye' to the end of the shaft and rigged a bottle-screw (note: I obtained a straighter lead than that shown in the pic before removal):

This is the removed shaft with 'eye':

And this the damaged end:

Not bad for a 'ringer' eh?

Once again, thanks for your help.

How do I separate the transfer box from the gearbox?

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