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Rebuilding my gearbox


LRzed
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My gearbox is popping out of 2nd and 3rd gear on deceleration.. 4th gear makes a clackety noise at light acceleration or coasting.

I've been advised that the transmission probably needs a couple of things, such as syncros or bearings. I've checked the nut on the rear of the main shaft already. It was loose but not backed out.

What I was really wondering is.

Is this the type of project that someone with moderate experience in automotive tinkering and nil experience in transmissions can take on?

I've successfully replaced oil seals and clutches, that's about the extent of it with gearbox work

I'm an office worker, not a mechanic. But I do all of my own work thus far.

What do you think.. in over my head?

Also, a second opinion would be nice. There is a slight amount of play.. a few mm when I push the shift lever into first or third. When I push forward on the shift lever it pushes the main shaft back a couple mm. That and the popping out of gear and noise. It doesn't grind or anything. Shifts smoothly. Just likes to pop out of gear.

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I just rebuilt my trans (and replaced two gears that were iffy). If the have the manual, it's not too bad to do. There is a snap ring that is a real pain in the A$$ to remove and replace. Follow the disassembly and reassembly guide to the letter, there is only one wat to do it right... but lots of ways to get it wrong (and it won't go together) It also helps to have someone around that can talk you through it if you get to a sticky spot. Here's a pic of mine disassembled. the pain in the rump snap ring is on the left of the gears shown in the foreground...

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I just rebuilt my trans (and replaced two gears that were iffy). If the have the manual, it's not too bad to do. There is a snap ring that is a real pain in the A$$ to remove and replace. Follow the disassembly and reassembly guide to the letter, there is only one wat to do it right... but lots of ways to get it wrong (and it won't go together) It also helps to have someone around that can talk you through it if you get to a sticky spot. Here's a pic of mine disassembled. the pain in the rump snap ring is on the left of the gears shown in the foreground...

Just the big green book manual? or a special gearbox manual?

Other than the forums, there's no one around to "talk me through it"

Judging by the bits around your shop.. you seem a bit more experienced than I.

THanks..

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LRzed,

I did mine recently and although it was a bit daunting at the start, it was all fairly logical.

My Gearbox Rebuild Thread with many valuable tips from others!

  • As has been suggested already, the proper Gearbox Manual is vital for clearances and assembly instructions. (Available from the links in the Technical Archive for nowt).
  • I'd also suggest a marker pen and a big sheet of paper so you can lay stuff out in sequence as you pull it apart. Write notes on the paper. I also wrote on most components, eg "This side to front".
  • The only specialist tool I needed to buy was a giant set of circlip pliers for the bearing housing at the back of the main box. I made the castleated (sp?) nut removers for the two nuts because I wanted to be able to torque them properly rather than chap them round with a blunt instrument.
  • As you can see on the thread linked above, post photos of any doubtful bits and somone will be able to help you.

For Parts:

In my experience, Allan at LEGS was very helpful and responded quickly to E-Mails.

John Craddocks site is useful for ordering as it lists all of the Part Nos. in their pick list.

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Rebuilding a series transmission isn't that hard to do, just follow the manual using normal hand tools, you'll do fine.

The Series 3 WSM can be downloaded on the internet, but if you can't find it, I'll send (email) you a copy.

As mentioned byFatboy, buy your parts from a company that deals with transmissions on the daily bases. Your chances of buying poor quality parts from them will be nil. A lot of these mail order aftermarket suppliers sell poor quality parts, do you want to strip the trans again in a few years?

Cheers,

Todd.

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As stated, Haynes or LR Manual a must. Very straight forward to do in the right sequence.

The only thing I would add is to make sure you have a decent clean work area. Cleanliness is essential, and it is also a good thing to be able to lay components on the bench in the correct order for assembly.

I did mine, I had never done anything like it before, I found it very satisfying to do, and it worked well 1st time and has done 1000's of miles without a hint of trouble. It also gave me the confidence to rebuild my engine, which is also easier than it sounds.

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PAH! look at that messy workbench! :P

If you're going to do the whole transmission, then treat the gearbox and transfer box as seperate items and rebuild them seperately as well. The Haynes manual is basic, but the L/R workshop manual is more detailed and you are likely to do a better job by using it. If you can - take pictures/make notes - especially with regard to what gear goes where (and what way round it goes!)

I recently rebuilt a suffix 'D' gearbox/transfer case, and apart from fitting shims/ measuring clearance/doing it all again to get it right - it all went very well. I even managed to make it look a little blingy :lol:

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Les.

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why dont you buy a box from ebay they go for around fifty quid and have a go at rebuilding that if all goes well you just have to swap box s if you $uck it up you are still on the road if you do a good job you can then rebuild your old box sell it as a recon and probably cover your costs as well good luck

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  • 3 weeks later...
why dont you buy a box from ebay they go for around fifty quid and have a go at rebuilding that if all goes well you just have to swap box s if you $uck it up you are still on the road if you do a good job you can then rebuild your old box sell it as a recon and probably cover your costs as well good luck

I'm not currently in the UK. I picked up a gearbox from a IIA that has III internals. I haven't exchanged them yet. But my plan is to rebuild the III while using the IIA.

A transmission here will cost an easy £1000 plus freight for another 250. I'm currently mid pacific. Big parts don't come easy out here.

Small parts aren't that much more expensive than in UK but the heavy and the rare (which a lot of it is rare outside UK and AUS) end up being expensive.

I am currently using a california based company. But am thinking about trying to get some of the UK suppliers to ship here. But shipping can take 60 days or more, or cost hundreds to speed up.

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