jasonslaphead Posted March 17, 2011 Share Posted March 17, 2011 have been tracing down a clunk, was hoping it would be a cheap bush or something but couldnt find anything obvious so I pulled off the pto cover to take a look thinking the transfer box input gear would come off but it didnt so couldnt see the splines on the gearbox output shaft. made a video of the play, i'm pretty sure its excessive but looking for confirmation video here its not great quality but you can see whats going on while I rotate the handbrake drum back and forth Quote Link to comment Share on other sites More sharing options...
Les Henson Posted March 17, 2011 Share Posted March 17, 2011 You should be able to remove the input gear by rocking the handbrake drum and manipulate the gear off as you do so. If the splines are worn (and they do look a bit buggered ), then removal of the gear is more difficult for the simple reason that the outer section of the shaft is undamaged, so there's a step in each of the splines. The rusty-coloured bits that you can see in the centre of the input gear is the particles of metal that come off and mix with a small amount of oil are an indicator of spline/gear wear. Les. Quote Link to comment Share on other sites More sharing options...
reb78 Posted March 17, 2011 Share Posted March 17, 2011 I cant remember how wide the spline are when new, but whilst those splines look partly worn, you might get away with replacing the input gear to remove some of the play at this stage. The splines on one of my old boxes were sharp points about 1mm across and that still drove (although i think it would have given up soon if driven for much longer!) If you do replace the input gear, make sure to get a cross drilled one. Quote Link to comment Share on other sites More sharing options...
jasonslaphead Posted March 17, 2011 Author Share Posted March 17, 2011 will have another go at getting the input gear off tomorrow to get a propper look at the splines Quote Link to comment Share on other sites More sharing options...
jasonslaphead Posted March 19, 2011 Author Share Posted March 19, 2011 having fun trying to get the input gear off, dont want to budge at all. any ideas ? Quote Link to comment Share on other sites More sharing options...
Les Henson Posted March 19, 2011 Share Posted March 19, 2011 You've pretty-much {u}got{/u} to remove it, although removing the transfer box might also work (it should fall off then). If a step in the splines is preventing the gear from coming off, then it may also prevent the transfer box from being removed. Les. Quote Link to comment Share on other sites More sharing options...
TheHarv Posted March 19, 2011 Share Posted March 19, 2011 so I pulled off the pto cover to take a look thinking the transfer box input gear would come off but it didnt at the risk of asking the bleedin obvious have you also removed the actual rear bearing retainer plate? Quote Link to comment Share on other sites More sharing options...
jasonslaphead Posted March 19, 2011 Author Share Posted March 19, 2011 lol yes, took a lot of wobbling but it came off in the end. the input gears teeth are pretty worn with a lip at one end think thats what was making it hard to get off. definately need an input gear cant see the output shaft very well in the dark under there but I presume they are just as bad. Quote Link to comment Share on other sites More sharing options...
jasonslaphead Posted March 19, 2011 Author Share Posted March 19, 2011 input gear splines are a bit triangle shaped output shaft doesnt seem as bad as I expected, probably best replaced though Quote Link to comment Share on other sites More sharing options...
Les Henson Posted March 19, 2011 Share Posted March 19, 2011 I did an economy repair on a disco once (input gear only), and it clunked just as bad as before. Les. Quote Link to comment Share on other sites More sharing options...
jasonslaphead Posted March 19, 2011 Author Share Posted March 19, 2011 probaly go for a replacement box have a long trip planned in a few months and dont want stuff breaking on me overseas Quote Link to comment Share on other sites More sharing options...
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