Transfer box gear selection!

Peaches · Dec 19, 2012

I'm fitting another gearbox/transferbox to my series after the old one developed a problem, but now its fitted I'm having issues with selection of low/high range. The lever on the new one moves far too far forward and wont properly engage high range before it hits the transmission tunnel. Also consequently, it doesn't drop it out of 4wd either.

The other issue is the clutch, which has too much free play in it. Is it possible that the clutch will require adjustment at the pedal even if the pressure plate has not been disturbed?

Any advice would be much appreciated, I've lost my means of transport now and I need the truck back on the road as quickly as possible!

Cheers,

Pete

Dr_evil · Dec 19, 2012

to drop out of 4wd stick into neutral then high or thats how I do it on mine

as to not going far enough forward you sure you've refitted the floor properly or put the thing in a notch or two out ?

Peaches · Dec 19, 2012

Just given that a go, but it seems the the transfer lever doesn't quite get the box into high range properly. Its definitely moving too far forward because i can compare it to the old box.

Dr_evil · Dec 19, 2012

bolted in fully ? main box in gear ?

Dr_evil · Dec 19, 2012

jm will be better for this I'm just throwing out suggestions……..

Peaches · Dec 19, 2012

Yup, tried every combination and doesn't seem to want to work for love nor money.

By all means thanks for the suggestions, christ knows I'm out of ideas!

Dr_evil · Dec 19, 2012

have you tried doing it whilst rolling ?

might be like my disco it wont engage again properly unless it moves a meter or so

Peaches · Dec 19, 2012

yeah, the situation is the same moving or static, the lever hits the bulkhead before the gears mesh properly. It is engaging, but only in the way that when you try and move with any throttle it jumps out of high range straight away.

Peaches · Dec 19, 2012

what I really need to know i reckon is if there is any adjustment on this bit, and how you do it. Haynes manual doesnt seem to think there is any.

Dr_evil · Dec 19, 2012

the levers not bent is it ?

Only thing I can think of if its not going in would be it being put in a couple of teeth out so not fully engaging with the main box ? or if the final gear in the main box that meshs in is loose ?

Peaches · Dec 19, 2012

hmmm, that sounds like a feasible cause of the issue. I think I may have to start tearing the seatbox back out again to get up close to it.

Dr_evil · Dec 19, 2012

final gear just remove the inspection panel if it has one and check the castle nut isn't loose although if it was loose I'm sure you would have had problems before this

as to teeth being out I had that on my disco when the t'fer box was done at the mechanics, even they can get it wrong once in a while through a simple slip. Might be able to get away with taking the box off without removing the seats. I can on mine as someone has replaced the weld in x-member with a bolt in one

Peaches · Dec 20, 2012

Sorted it now, the issue was a combination of the shaft protruding too much, and the lever being slightly bent. A gas axe and some muscle did the trick. Cheers for the help Dr.Evil!

Transfer box gear selection!

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