Ronnie90 Posted June 7, 2016 Share Posted June 7, 2016 Hi guys Need a little advice. Stripped and rebuilt my transfer box to cure the leaks it had everywhere, all seemed fine but a little tighter when turned output shafts once I'd finished which I thought might not be a bad thing. After refitting in the truck I can hear the input shaft is turning ok but the rest seems jammed/siezed when letting the clutch up, jumped forward once then stopped and jumped backwards once then stopped. If I was to let the clutch fully up it would stall the engine. Any ideas before I rip it out and start again. I was having trouble on the day I put it in the garage to strip it down but it was just the clutch fluid had run low. Quote Link to comment Share on other sites More sharing options...
robertspark Posted June 7, 2016 Share Posted June 7, 2016 Check the bolt lengths, I forget which side it is but there is a bolt that is slightly shorter than all the others or it can catch on the high range gear the one furthest from the diff end, back of the box Quote Link to comment Share on other sites More sharing options...
reb78 Posted June 7, 2016 Share Posted June 7, 2016 Robert beat me to it. Quote Link to comment Share on other sites More sharing options...
Ronnie90 Posted June 7, 2016 Author Share Posted June 7, 2016 I was praying somebody would say that as it was my one and only thought as to what it could be. Will check them tomorrow and report back. Thanks guys Quote Link to comment Share on other sites More sharing options...
muddychris300tdi Posted June 8, 2016 Share Posted June 8, 2016 I think it's the top rear transfer to gearbox mounting bolt that should be shorter. Quote Link to comment Share on other sites More sharing options...
oneandtwo Posted June 8, 2016 Share Posted June 8, 2016 Be warned that if this has happened, remove the input gear and feel for play in the intermediate gear on the shaft - when I did this the bolt forced the intermediate gear bearing locating circlip to deform and the result was a lot of slop in the gear Quote Link to comment Share on other sites More sharing options...
Ronnie90 Posted June 8, 2016 Author Share Posted June 8, 2016 That would be the stud below the hi/lo selector (below the Clevis) I have tried that bolt and others that I can get to but with no luck as yet. I'm wondering if the problem would be visible with the inspection hatch off. Quote Link to comment Share on other sites More sharing options...
Ronnie90 Posted June 10, 2016 Author Share Posted June 10, 2016 Having a bit of a dilemma, tried all the bolts and nothing is helping. Also I shouldn't have put it all back together as the splines on my gearbox output shaft are pretty worn as well. Normally I would just jump in and buy a recon one but work is a little quiet just now so trying not to spend too much. Anybody have any idea of the cost of having it rebuilt with a new shaft or even a second hand LT77 gearbox for sale with decent splines. When work picks up again I plan on rebuilding the car with a new galv chassis and bulkhead and was going to buy recon gearbox and transfer box then so this is a shift term solution I would like to keep costs down on. I'm in Fife, Scotland Quote Link to comment Share on other sites More sharing options...
Hazza Posted June 11, 2016 Share Posted June 11, 2016 You could try pulling the transfer box off and welding the gearbox splines then grinding them back to shape. It's not a long term solution but would get you moving again for very little cost. Mine's done about 2000 miles like this. Quote Link to comment Share on other sites More sharing options...
muddychris300tdi Posted June 11, 2016 Share Posted June 11, 2016 Have you tried it in low box and diff lock and out again? Quote Link to comment Share on other sites More sharing options...
Ronnie90 Posted June 11, 2016 Author Share Posted June 11, 2016 I've tried all combinations of gearing but had no joy, I have a couple of contacts to try for ideas and options but might just park it up and wait till I get a recon gearbox, will strip the transfer box down and get it working and replace the input gear in preparation for when I get a gearbox. Quote Link to comment Share on other sites More sharing options...
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