russellc Posted April 6, 2015 Share Posted April 6, 2015 The gearbox was getting stuck in 3rd gear. Encouraged by the gearbox rebuilt info online I set to it. Removed the gearbox, clutch housing, castle bolt and pulled out the Mainshaft and layshaft. I was surprised to find that there were no springs on the 3rd/4th synchromesh and the inside gear on the 1st/2nd synchromesh was broken. No pieces of metal in the oil either. I put new springs on the 3rd/4th sychro and replaced the 1st/2nd Sychro gear, then put it all back together. Felt like a tight fit, everything rotated as it seemed it should. Tightened up the castle bolt with a new lock washer, fitted the bell housing a a new clutch actuator. Laboured for hours getting the gear box into the vehicle, trying to line up the mainshaft into the clutch ( is there an easy way to do this?!) . Finally got lucky and bolted the clutch housing tight. Filled the oil, bled the clutch. Ready to try... It will not engage in any high range gear but will in low range! It changes gears nicely? Just will not engage when the clutch pedal is released. I can move in low range forward and reverse. What have I stuffed up? I'll attach a video if I can... Quote Link to comment Share on other sites More sharing options...
Keeper96 Posted April 6, 2015 Share Posted April 6, 2015 Just guessing here but I'd say it was possibly more to do with your transfer box than your gear box seeing as it works in low range. Not sure what it could be though. Sorry I can't help Jamie Quote Link to comment Share on other sites More sharing options...
discomikey Posted April 6, 2015 Share Posted April 6, 2015 Most likely to be an issue with your floor and transmission tunnel not letting the hi/low lever engage fully if you haven't rebuilt the transfer box. Try checking that you are getting full movement on the lever. Quote Link to comment Share on other sites More sharing options...
ian_s Posted April 7, 2015 Share Posted April 7, 2015 i had to bend the high/low lever on mine as it was hitting the tunnel. in that video that lever looks very close to the lip on the bulkhead? does it touch it? check your engine mounts, make sure you haven't pushed the engine forward if (like me) you got a bit angry when the clutch wouldn't line up! Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted April 7, 2015 Share Posted April 7, 2015 All looks very far forward to me.... echo comments about lever hitting bulkhead? Quote Link to comment Share on other sites More sharing options...
Serious Series Posted April 9, 2015 Share Posted April 9, 2015 The ball for the transfer lever does not appear to be fitting correctly in the bracket of the lever / shaft. Have you fitted the lower pivot point in the correct position? Ie the right side of the alloy casing at base. from memory think the steel should be at the rear of the alloy of the casing. Quote Link to comment Share on other sites More sharing options...
V8CAMEL Posted April 9, 2015 Share Posted April 9, 2015 From the sound in high box it does seem that in hi the transfer box is not fully engaged Quote Link to comment Share on other sites More sharing options...
Snagger Posted April 10, 2015 Share Posted April 10, 2015 The bracket that acts as the pivot for the transfer box lever can be fitted the wrong way around with these symptoms. I learned that the hard way. Quote Link to comment Share on other sites More sharing options...
Jon White Posted April 10, 2015 Share Posted April 10, 2015 Spot on snagged - I've done that too! Suspect that the problem is related to the lever mounts Quote Link to comment Share on other sites More sharing options...
Serious Series Posted April 16, 2015 Share Posted April 16, 2015 Six days and no feedback ? Come on let us know how it's going. Quote Link to comment Share on other sites More sharing options...
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