Output shaft housing on Series 2A removal

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Monkey Welds

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Hi all - I've managed to jam the 4wd selector shaft into the output shaft housing (trying to free it from corrosion, made it worse...) so i need to know this: is it possible to separate the housing from the transfer box so i can get inside it to free off the stuck shaft? I have the gearbox out but all the info i can see seems to suggest that the whole gearbox has to be split apart to access this one bit. There's no way i could tackle a gearbox rebuild, it's too complex for me. Please someone, tell me i can gain access to the interior of the output shaft housing with just some basic work. I'm terrified of trying to seperate it apart then watching a load of gears, etc drop to the floor as it seperates! Thanks, Phil.
 
Hi all - I've managed to jam the 4wd selector shaft into the output shaft housing (trying to free it from corrosion, made it worse...) so i need to know this: is it possible to separate the housing from the transfer box so i can get inside it to free off the stuck shaft? I have the gearbox out but all the info i can see seems to suggest that the whole gearbox has to be split apart to access this one bit. There's no way i could tackle a gearbox rebuild, it's too complex for me. Please someone, tell me i can gain access to the interior of the output shaft housing with just some basic work. I'm terrified of trying to seperate it apart then watching a load of gears, etc drop to the floor as it seperates! Thanks, Phil.
Firstly, it's really unlikely that the problem is inside the box. Try taking off the tin cover with the two 'tubes' and cleaning all that area up because it's probably clagged up with rust and dry grease. That and a really good clean of the eternal mechanisms should see it working again.

But to answer your question, you can't just take the front housing off, there's (not much) other stuff to do inside. BUT this is not a complicated gearbox, and would be a good confidence builder for someone who wanted to go further.
 
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Firstly, it's really unlikely that the problem is inside the box. Try taking off the tin cover with the two 'tubes' and cleaning all that are up because it's probably clagged up with rust and dry grease. That and a really good clean of the eternal mechanisms should see it working again.

But to answer your question, you can't just take the front housing off, there's (not much) other stuff to do inside. BUT this is not a complicated gearbox, and would be a good confidence builder for someone who wanted to go further.
Thanks for the info - I've decided to dive straight in and take out the gearbox, though i suspect yours and my idea of complicated might be slightly different! Hopefully i'll be able to get it back together in one piece...
 
Firstly, it's really unlikely that the problem is inside the box. Try taking off the tin cover with the two 'tubes' and cleaning all that are up because it's probably clagged up with rust and dry grease. That and a really good clean of the eternal mechanisms should see it working again.

But to answer your question, you can't just take the front housing off, there's (not much) other stuff to do inside. BUT this is not a complicated gearbox, and would be a good confidence builder for someone who wanted to go further.
Don’t do it. Nothing but lies and distraction. All series cogs are spring loaded and put holes in the garage roof the second you touch a bolt. They also change shape and position at will like Harry Potters stairs. Anything with more than three cogs is witchcraft and frightens the bejesus out of ya.
:eek::D
 
Thanks for the info - I've decided to dive straight in and take out the gearbox, though i suspect yours and my idea of complicated might be slightly different! Hopefully i'll be able to get it back together in one piece...
Get the parts book and workshop manual. Parts books are often better at showing the order of bits.

But, I still say the answer is more like on the outside.
 
Don’t do it. Nothing but lies and distraction. All series cogs are spring loaded and put holes in the garage roof the second you touch a bolt. They also change shape and position at will like Harry Potters stairs. Anything with more than three cogs is witchcraft and frightens the bejesus out of ya.
:eek::D
@Bobsticle reminds me. In the front housing there is one assembly with springs. Fer fu.....ake don't take it apart unless you've got the parts book. Or the spells book. I'll happily email you the former, but the book of spells doesn't leave my sight.
 
Thanks guys. For anyone with the same problem viewing this thread, i can confirm that once the pinch bolt is released through the inspection cover, the output shaft can be removed relatively easily. I had the gearbox bellhousing pointing upwards so that nothing would fall out to the floor when lifting up the cover. One new £32 selector shaft later all is working well.
 
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