ivancrx · May 25, 2017

Having a few problems for a change, 200tdi with LT77 Gear Box.

I have just fitted a refurbished gearbox, when it isn't running I can get reverse, first, second third and fourth but no reverse. It all moves through the gears fine except for the fifth.

Start it up with clutch pressed and still only get reverse, first, second third and fourth again no fifth.

Release the clutch with what should be in neutral and it is still in gear and lurches forward?

Anyone have any ideas? New clutch, fitted 1500 miles ago along with clutch master and slave cylinders.

mojo247 · May 25, 2017

if I remember rightly, 5th is out on its own, top right. either the 5th gear stop has moved in the gear lever housing (see below) or you have some issue with the 5th gear shaft.

not sure about why neutral isn't working, again probably some issue with the shafts.

Some parts info on here: http://www.retroanaconda.com/landrover/parts_books/110/4_gearbox_transfer_box_p300-397.pdf

mojo247 · May 25, 2017

@jamesmartin

jamesmartin · May 25, 2017

ivancrx said:
Having a few problems for a change, 200tdi with LT77 Gear Box.

I have just fitted a refurbished gearbox, when it isn't running I can get reverse, first, second third and fourth but no reverse. It all moves through the gears fine except for the fifth.

Start it up with clutch pressed and still only get reverse, first, second third and fourth again no fifth.

Release the clutch with what should be in neutral and it is still in gear and lurches forward?

Anyone have any ideas? New clutch, fitted 1500 miles ago along with clutch master and slave cylinders.

can you feel and hear it engage the gears it does? take the top off and look at the quadrant on the shaft if you google frc7330 look at a pic the right angle cutout should sit on lhs of the box ie passenger side also google image frc4905 if you ensure 5th is in neutral it should sit over the raised flange on the interlock on selector shaft

Saint.V8 · May 25, 2017

jamesmartin said:
can you feel and hear it engage the gears it does? take the top off and look at the quadrant on the shaft if you google frc7330 look at a pic the right angle cutout should sit on lhs of the box ie passenger side also google image frc4905 if you ensure 5th is in neutral it should sit over the raised flange on the interlock on selector shaft

ivancrx · May 25, 2017

I'm not back home yet so will investigate when I get in.

Many thanks for the bunny made my afternoon

ivancrx · May 28, 2017

Well I think I have found the problem.
The interlock spool isn't connected to the 5th gear selector fork

Now my big question, is there anything I can do to sort this out or does the gearbox need to come out and be stripped?

Any ideas?

@jamesmartin

jamesmartin · May 28, 2017

if you knock pin out of the quadrant on rear of selector shaft and remove the front interlock on top middle of main case you can fully rotate shaft as long as 1/2 and 3/4 are in neutral

ivancrx · May 28, 2017

jamesmartin said:
if you knock pin out of the quadrant on rear of selector shaft and remove the front interlock on top middle of main case you can fully rotate shaft as long as 1/2 and 3/4 are in neutral

Is it just a case of knocking it through?

jamesmartin · May 28, 2017

ivancrx said:
Is it just a case of knocking it through?

pulling up front interlock and rotating selector shaft

ivancrx · May 28, 2017

jamesmartin said:
pulling up front interlock and rotating selector shaft

Thank you

ivancrx · May 29, 2017

I am still having problems with this.

I have removed the quadrant and the middle interlock not a problem. selector will now spin but it won't lock in to the 5 gear selector fork, it is though the selector fork is too far back in the box. The interlock spool id a good 1/4" out from the selector fork.

jamesmartin · May 29, 2017

ivancrx said:
I am still having problems with this.

I have removed the quadrant and the middle interlock not a problem. selector will now spin but it won't lock in to the 5 gear selector fork, it is though the selector fork is too far back in the box. The interlock spool id a good 1/4" out from the selector fork.

it should if you lever 5th into gear by the selector fork rotate enough to go go forward to engage the fork slot

ivancrx · May 29, 2017

jamesmartin said:
it should if you lever 5th into gear by the selector fork rotate enough to go go forward to engage the fork slot

Thank you for the very quick reply, there doesn't seem any play in the selector fork at all or am I not being brutal enough?

jamesmartin · May 29, 2017

ivancrx said:
Thank you for the very quick reply, there doesn't seem any play in the selector fork at all or am I not being brutal enough?

have you prised it into 5th

ivancrx · May 29, 2017

jamesmartin said:
have you prised it into 5th

I can't seem to get any movement form anywhere inside the box

jamesmartin · May 29, 2017

ivancrx said:
I can't seem to get any movement form anywhere inside the box

rotate main shaft while prising 5th fork into gear

ivancrx · May 29, 2017

jamesmartin said:
rotate main shaft while prising 5th fork into gear

Gearbox is actual all bolted in, sorry to sound silly but would it turn if I just turn the engine over by hand?

jamesmartin · May 29, 2017

ivancrx said:
Gearbox is actual all bolted in, sorry to sound silly but would it turn if I just turn the engine over by hand?

jack a rear wheel and turn the hand brake drum

ivancrx · May 29, 2017

jamesmartin said:
jack a rear wheel and turn the hand brake drum

I would just like to say massive thank you for your help with this, I now have all my gears and in the right place and a neutral when it is running.

Again thank you.

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