Monkey Welds said:

Hi all - I've managed to jam the 4wd selector shaft into the output shaft housing (trying to free it from corrosion, made it worse...) so i need to know this: is it possible to separate the housing from the transfer box so i can get inside it to free off the stuck shaft? I have the gearbox out but all the info i can see seems to suggest that the whole gearbox has to be split apart to access this one bit. There's no way i could tackle a gearbox rebuild, it's too complex for me. Please someone, tell me i can gain access to the interior of the output shaft housing with just some basic work. I'm terrified of trying to seperate it apart then watching a load of gears, etc drop to the floor as it seperates! Thanks, Phil.

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boguing said:

Firstly, it's really unlikely that the problem is inside the box. Try taking off the tin cover with the two 'tubes' and cleaning all that are up because it's probably clagged up with rust and dry grease. That and a really good clean of the eternal mechanisms should see it working again.

But to answer your question, you can't just take the front housing off, there's (not much) other stuff to do inside. BUT this is not a complicated gearbox, and would be a good confidence builder for someone who wanted to go further.

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boguing said:

Firstly, it's really unlikely that the problem is inside the box. Try taking off the tin cover with the two 'tubes' and cleaning all that are up because it's probably clagged up with rust and dry grease. That and a really good clean of the eternal mechanisms should see it working again.

But to answer your question, you can't just take the front housing off, there's (not much) other stuff to do inside. BUT this is not a complicated gearbox, and would be a good confidence builder for someone who wanted to go further.

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Monkey Welds said:

Thanks for the info - I've decided to dive straight in and take out the gearbox, though i suspect yours and my idea of complicated might be slightly different! Hopefully i'll be able to get it back together in one piece...

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Bobsticle said:

Don’t do it. Nothing but lies and distraction. All series cogs are spring loaded and put holes in the garage roof the second you touch a bolt. They also change shape and position at will like Harry Potters stairs. Anything with more than three cogs is witchcraft and frightens the bejesus out of ya.

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