tweetyduck

Don't cut corners. change the races and bearings. Change as much as you can afford to change. Don't skip something just because it looks a little difficult. You only want to do this once ! Find a brass punch or piece of brass bar and use a hammer. They all come off eventaully.

I do not think its possible for the case to wear that much.

10mm is a lot. the case does not look worn and to be honest it would be impossible to wear that much away. Theres only 10 parts the the inter shaft assembly including all the O rings and nuts etc. So Gear, Crush Spacer, 2 x Bearings, 2 x O rings, Shaft, Plate, Bolt, Lock Nut. How theres a 10mm gap is a mystery. However you are correct about the case being squeezed to take up the float but NOT 10mm! Possibly 1mm max!

I think there are four bolts/studs. The are three you can see from the back of the box and one you undo from the front of the box. From memory.

You missed the front bolt.

Talking of overlanding i wanted to ask you about putting LSDs or ATBs on my very heavy, very cumbersome Pulse. I just think it will have a predisposition to get itself stuck no matter how carefull i am as its practically a tank with slicks. Maybe this is a conversation or another thread?

Thanks VM. Normally what happens now is you'll not see me for 5 months, well at least one as i'm running down to Morocco with 4 others in tow (for free as i'm not a tour operator !) Thanks Again.

Jees whats a guy to go to get Long Term round here ! 50 + 40 + 20 = 11 years subs if its advised at £10 pa. an i think i've only been here 7 ? maybe...not sure.

There's another £20 in your "slush fund" "Christmas Drinks Fund" ... LOL

Nige i did one £40 on 2nd October 2014 for sure as i have Paypal back that far. I did one before that for like £50 but i have no idea when. If it £24 per year i'm overdue. LOL but then again i'm overdue on everything !

i'm sure it will be fine i don't do Standing Orders but think i've done a couple of payments or maybe i'm imagining it...LOL I know i did £40 right after my trip on my first pay packet as i'd been fleeloading since before i went but have no more evidence for my lack of generosity. I could have sworn i'd done two but as is the way with paypal, no records past not very long ago. Such is the online banking world......i liked paper.

So i'm under review. Having donated i think £100 i would have thought i'd never get this?

With the main square plate off the box you can remove the nut and shaft from the transfer box and remove the entire intermediate gear assembly and put it back in with nothing more than and new crush spacer and a new nut. The shaft cannot be removed backwards but must be removed forwards and this cannot be done (i think) with the gearbox and transfer attached so unless the box is out you cannot do what i've said. But once its out its VERY easy. Replacing it with a new crush spacer in place and the gears back in place is a simple as tightening up the nut until there is no movement in the gears front to back. You can replace the o rings also which sit in the case and on the shaft at teh front end.

Ypu will need a couple of O rings of course. Again depending on Serial. FRC8292

Depending on Box serial Spacer Collapsing Intermediate Shaft FRC7437 Circlip FRC7454 Bearings x 2 STC3185 Shaft FRC8291

Whats the serial number of the box.

Agree.Recon box is £500 and book time is 8 hours to replace. So considering sundries and stuff. £900 is OK. 10 hours at £40. I'd get a fixed price quote and take them up on the offer but ONLY once you know for sure. Get them oils drained and get some covers off.

I'd empty both Trans and Gearbox of oil and see what it looks like. Empty them fast so any big bits are dragged out. Take a look at both oils carefully. Use clean containers. That will almost certainly tell you which box it is. You really need to start looking rather than asking. The Gearbox bearing cannot be changed easily. Its a box out and then box strip really. This cannot be done yourself unless you have tools, press and pullers. If the bearing is gone then it will have destroyed the Mainshaft quite probably. However, if you have the box out you can (I THINK!) pull off the oil seal collar and replace both the seal, bearing and collar in situe without splitting the box. However if you've got that far you might as well split the box and do the entire job.

output bearing on the R380. Usually the place they go and causes these symptoms. I know cos i've had one go. The bearing is hard to get and will have trashed the shaft. Currently only RHP make the bearing.

its takes two although with a lot of swearing you can get a tranfer out on your own. I've done it more than once with no equipment other than a wratchet strap and a piece of wood from one window to the other.

Having rebuild both a Gearbox and Transfer on the floor in a garage on my trip i'm at a loss what would cause noise only when under load. The only thing i can think of is its a bearing....but which one. My bet so far is R380 rear support bearing as thats usually what goes due to load and would so be affected by loading. Its the one directly above the oil pump on the rear of the Gearbox. Either waey you will have to start removing stuff. So if you take out the Trans you will see the Gearbox output shaft. That where the bearing is. You might be able to feel the problem.

I'm not aware of an Arial connector but if you mean the massive one thats on the front right of some Pulses. The massive box thing? then having checked the wiring diagram for the fitted for radio its difficult to tell. I would need more info and photos to assist. The Pulse wiring does not cover the radio version. I will do more digging but some more descriptions would help.

Pulse?

Thanks. i was expecting a simple rubber one. seems like this is the later one so maybe the earlier one is simple rubber?

another shot.