Oh dear I have a hole in my gearbox

Thanks James.
It selects gear fine, and will stay in gear anywhere between 3 and 20 miles - so I wouldnt have thought it is seized? Especially as it has all been stripped apart? Good thought about checking the nut on transfer box. That is pretty much all I can do really isn't it before taking it apart?

If it's jumping out of gear I don't think it would be the syncro rings, more like the selecter locking balls and springs.
As for the problem with 4wd that would be just in the transfer box
Trouble is your gonna have to take it all out again for inspection

i thought you said you couldnt get yellow knob to stay up thats the shaft seizing bit

Ah, yeah, sorry James thought you were referring to the main box r.e it seizing...the daft thing was, we testing the 4wd off the vehicle and it was fine!

Taking it all out again...fun fun fun! ..for the third time since I have owned the vehicle...I should be getting good at it now!

Well will be soon taking the overdrive off and checking the mainshaft nut. Thought it would be a good idea to get a tool to tighten it properly - but then thought against it when i saw the price - £40 on ebay for a non-genuine one. Yeah right! So made this...its not pretty but it works

Mainshaft nut was very loose! The tabbed washer was broken...nut was barely finger tight!

But...it did not fix the problem. Bugger!

still jumps out of gear if both and is going far enough to engage properly then it is box out unfortunately

Indeed! Fun fun!

Took the box out last night....getting quite quick at doing this! 3rd/4th Syncro is worn so suspect that is the issue, should have replaced it first time round! Oh well.

did you get 4wd etc working

Seems the 4WD was just a bit sticky - pulled the lever up a bit while toggling low/high box and it seems to have freed up So no longer in permanent 4WD...just need to replace the bits and re-fit again. Will post a pic f how bad the syncro is later! The gears have virtually no wwear at all so not going to replace those, although I have noticed the 2nd selctor fork has a nice groove worn into it, so going to replace that as well

Thought i'd post a few pics up, why not!

Gearbox coming out:







And the offending part...the teeth should not be spikey like that! The teeth have uneven wear - perhaps the syncro was getting stuck?

doesnt look too bad but cant see the sides which way round was it,the side were splines dont reach the end goes towards 3rd gear as shown in picture

Cant remember what way round it was! It reall is bad...some of the teeth have nice edges, the others are almost like needles!

check end float on third gear,more than 8 thou is liable to start jumping out of gear,the way round is very important as cut away splines is for snap ring holding 3rd to sit in otherwise it will not over center properly and lock in gear

Thanks James, that sounds like a valuable bit of information

Syncro replaced, still doing the same thing. bugger! Thought it might be the springs but was not those either.

Jumps out of gear between every 5 and 10 miles both in and out of overdrive. Doesn't seem to be went regular pattern trip it such as when under load etc.