samc88
Drivels spiritual representative
As some of you will know from other threads, I do have a spare series 3 gearbox which I've been toying with the idea of a strip down with to see whats inside ( as I've never done a gearbox before )and either rebuild it or see what good spares I can use. This isnt complete, lacking a bellhousing, top cover and gear behind the mainshaft (I presume it used to have an overdrive fitted). Anyway, here is the tale of how I stripped it down, hopefully it will be of interest to some.
Here it is on the bench
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152160_zps378eada2.jpg&hash=bbb8456edd8043c44c213a0720195dc4)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152161_zps69c3a98b.jpg&hash=998bea157b18c5f4b5ee8a8fb5781dfe)
First thing I did was to remove the transfer plate bottom cover using a 7/16ths spanner to undo the 10 nuts holding it on
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152164_zpsb5be2dc6.jpg&hash=e892134c7b3245a9150587b63fb642d4)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152166_zps6c21b930.jpg&hash=d3e0fbc108d745835e1c8c82a2006117)
Most of the nuts except 3 came out with the studs. So I decided to take all the studs out and when it comes to reassembly I'll put them all in with locktite.
The transfer plate was then removed by knocking a thin scraper all around to try and break the seal made by the gasket. Do this gently so as to avoid damaging the plate or casting.
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152169_zps86d71adb.jpg&hash=c17728ecfcd2c155c4cf51f303792c86)
Revealing some gears:
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152170_zpse4ae932e.jpg&hash=4f280ebb9bb72b4148e0dac6e9205476)
There is quite a lot of debris in there (I think this is from when it had a period of being stored outside though)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152171_zpsee758f95.jpg&hash=0ba4fedfffb3435d5551463ee2430cf9)
The nut and spring washer securing the intermediate shaft was removed using a 15mm spanner
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152172_zpsba145100.jpg&hash=f20863966a793af69cce96a1baaa3aa4)
To get better access I tipped the gearbox over (i.e. so the transfer box plate would be underneath) and a nut fell out:
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152173_zps4f4b4719.jpg&hash=f0a3e9ce5c7017009616dda26f0ceb37)
Then of course I tipped it back up revealing![Eek! :eek: :eek:](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152174_zpse767f410.jpg&hash=4709da93147c93c0bdbb29738925f745)
Yes all this had been dropped in the transfer box! I wouldnt imagine it would last very long if it was run with all this in there
Land Rover state to use a special tool to grip into the grooves on the intermediate shaft end but I imagine this to be jolly expensive so I managed with a pry bar and a hammer to knock it out![Big Grin :D :D](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152175_zps1621d70e.jpg&hash=865c984b2e4c7264abbf201c5ff710ff)
Anyone with a bit more common sense than me will probably see the next problem a mile off, yes of course I realised there isnt enough clearance to get the shaft out so had to remove the hand brake back plate.
First the split pin and castle nut were removed with a 1" socket on a breaker bar. The box has to be locked up for this. On a complete box its easy, you can just put it in gear (which is what I did on my other box when doing the rear oil seal), on one like this its a bit more awkward.
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152176_zps0f3ae214.jpg&hash=f9dc2b5bb73878f6a89d259fb3c8956a)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152177_zps845dec30.jpg&hash=0b65ecee939ed7b85952c6a73208537c)
this could then be removed allowing access to remove the backing plate. Note there is a felt washer behind it
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152181_zps2394dcfc.jpg&hash=92ee060cfb270998f7f88b4b376cfdc6)
The nut, washer, felt washer and main part were cabledtied up to keep them together![Smile :) :)](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152178_zps0116a22c.jpg&hash=e9b91f95d16e46276084d4fd90936a8d)
The 4 nuts and spring washers holding the back plate on were removed with a 15mm spanner
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152185_zps0885282b.jpg&hash=a2cecd4e66ce9f90377dd5630d8bb886)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152186_zps5379deff.jpg&hash=b6860aa236a697b343cbb45a3dc3e36e)
As you can see, the shaft now has plenty of clearance to come out![Smile :) :)](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152188_zps24622ae2.jpg&hash=b98377c7b1ae23c0bb3353f698e483a8)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152189_zpsf79675a3.jpg&hash=d1077176484fde556436536c6d123c7b)
Then the intermediate gear can be rolled out of the casing
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152190_zpsc9792eca.jpg&hash=22ba27b47d8d171f9e8891c8ed64cae8)
Inside this is a long roller bearing
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152191_zps4c77eb30.jpg&hash=1d7a90885cc5637ce12635ad1e48fb3a)
Next the thrust washers either side of the gears in the casing were removed
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152192_zpsae875985.jpg&hash=4bdd7e9211f481101703b3584530a7bf)
Judging by the colour difference either side of each one, I'd say they are worn? Do you agree?
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152195_zps29687bcd.jpg&hash=4c87886f7514b9b49bfa48d9ecb1ab60)
Next, the last job of tonight was to loosen off the external (there should be 5 on a complete box, I had 3) and internal (3 of them) fasteners using a 15mm spanner and socket.
External example:
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152197_zps43031045.jpg&hash=98d8e60d3c574a3077b80377d2513829)
Where 2 of the internal ones are, the third is behind the mainshaft in this pic
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152198_zps501634cc.jpg&hash=8f35ba34e0f4546a10f710b3ff411562)
So there we have it
Tomorrow I'll hopefully get the boxes split ![Smile :) :)](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)
Do any of the parts so far look a bit life expired to you?
(Also regarding the books, I have nothing against them they were just handily nearby and of the right size the help stop the gearbox toppling over when doing the castle nut
If I had some wood I would have used that
)
Here it is on the bench
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152160_zps378eada2.jpg&hash=bbb8456edd8043c44c213a0720195dc4)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152161_zps69c3a98b.jpg&hash=998bea157b18c5f4b5ee8a8fb5781dfe)
First thing I did was to remove the transfer plate bottom cover using a 7/16ths spanner to undo the 10 nuts holding it on
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152164_zpsb5be2dc6.jpg&hash=e892134c7b3245a9150587b63fb642d4)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152166_zps6c21b930.jpg&hash=d3e0fbc108d745835e1c8c82a2006117)
Most of the nuts except 3 came out with the studs. So I decided to take all the studs out and when it comes to reassembly I'll put them all in with locktite.
The transfer plate was then removed by knocking a thin scraper all around to try and break the seal made by the gasket. Do this gently so as to avoid damaging the plate or casting.
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152169_zps86d71adb.jpg&hash=c17728ecfcd2c155c4cf51f303792c86)
Revealing some gears:
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152170_zpse4ae932e.jpg&hash=4f280ebb9bb72b4148e0dac6e9205476)
There is quite a lot of debris in there (I think this is from when it had a period of being stored outside though)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152171_zpsee758f95.jpg&hash=0ba4fedfffb3435d5551463ee2430cf9)
The nut and spring washer securing the intermediate shaft was removed using a 15mm spanner
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152172_zpsba145100.jpg&hash=f20863966a793af69cce96a1baaa3aa4)
To get better access I tipped the gearbox over (i.e. so the transfer box plate would be underneath) and a nut fell out:
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152173_zps4f4b4719.jpg&hash=f0a3e9ce5c7017009616dda26f0ceb37)
Then of course I tipped it back up revealing
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152174_zpse767f410.jpg&hash=4709da93147c93c0bdbb29738925f745)
Yes all this had been dropped in the transfer box! I wouldnt imagine it would last very long if it was run with all this in there
Land Rover state to use a special tool to grip into the grooves on the intermediate shaft end but I imagine this to be jolly expensive so I managed with a pry bar and a hammer to knock it out
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152175_zps1621d70e.jpg&hash=865c984b2e4c7264abbf201c5ff710ff)
Anyone with a bit more common sense than me will probably see the next problem a mile off, yes of course I realised there isnt enough clearance to get the shaft out so had to remove the hand brake back plate.
First the split pin and castle nut were removed with a 1" socket on a breaker bar. The box has to be locked up for this. On a complete box its easy, you can just put it in gear (which is what I did on my other box when doing the rear oil seal), on one like this its a bit more awkward.
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152176_zps0f3ae214.jpg&hash=f9dc2b5bb73878f6a89d259fb3c8956a)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152177_zps845dec30.jpg&hash=0b65ecee939ed7b85952c6a73208537c)
this could then be removed allowing access to remove the backing plate. Note there is a felt washer behind it
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152181_zps2394dcfc.jpg&hash=92ee060cfb270998f7f88b4b376cfdc6)
The nut, washer, felt washer and main part were cabledtied up to keep them together
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152178_zps0116a22c.jpg&hash=e9b91f95d16e46276084d4fd90936a8d)
The 4 nuts and spring washers holding the back plate on were removed with a 15mm spanner
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152185_zps0885282b.jpg&hash=a2cecd4e66ce9f90377dd5630d8bb886)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152186_zps5379deff.jpg&hash=b6860aa236a697b343cbb45a3dc3e36e)
As you can see, the shaft now has plenty of clearance to come out
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152188_zps24622ae2.jpg&hash=b98377c7b1ae23c0bb3353f698e483a8)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152189_zpsf79675a3.jpg&hash=d1077176484fde556436536c6d123c7b)
Then the intermediate gear can be rolled out of the casing
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152190_zpsc9792eca.jpg&hash=22ba27b47d8d171f9e8891c8ed64cae8)
Inside this is a long roller bearing
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152191_zps4c77eb30.jpg&hash=1d7a90885cc5637ce12635ad1e48fb3a)
Next the thrust washers either side of the gears in the casing were removed
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152192_zpsae875985.jpg&hash=4bdd7e9211f481101703b3584530a7bf)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152193_zps040324f9.jpg&hash=f558c2c815d59d9ceb8a25c9f71417ce)
Judging by the colour difference either side of each one, I'd say they are worn? Do you agree?
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152195_zps29687bcd.jpg&hash=4c87886f7514b9b49bfa48d9ecb1ab60)
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152196_zps325de86e.jpg&hash=fbfcbe87ca0e80cd4f5a01bc2d963c74)
Next, the last job of tonight was to loosen off the external (there should be 5 on a complete box, I had 3) and internal (3 of them) fasteners using a 15mm spanner and socket.
External example:
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152197_zps43031045.jpg&hash=98d8e60d3c574a3077b80377d2513829)
Where 2 of the internal ones are, the third is behind the mainshaft in this pic
![](/lz/proxy.php?image=http%3A%2F%2Fi1360.photobucket.com%2Falbums%2Fr645%2Fsamclarke95%2FP2152198_zps501634cc.jpg&hash=8f35ba34e0f4546a10f710b3ff411562)
So there we have it
Do any of the parts so far look a bit life expired to you?
(Also regarding the books, I have nothing against them they were just handily nearby and of the right size the help stop the gearbox toppling over when doing the castle nut
Last edited: