youve got two from front then top one under hi/low lever ,thewse 2 are the shortest and need to back ,a longer bolt will go threough and jam intermediate gear ,if you lever transfer box using gearbox drain bung as lever point it should create a gap big enough to get bar between the two boxes ,remember there are 2 dowels that can stay in either box when pulled apart so need checking before refitting,the lowest rear bolt also needs to be shorter than others as goes into blind hole i have known people split rear housing of gear box,by putting to long one in
 
funny when somone complains that they let the hand brake off it doesn't move as they've pinned the intermediate gear with a long bolt common issue!!
 
All I want for Christmas is me two front Teeth?? :eek:

DSC_3750.jpg


DSC_3745.jpg


Think I found the Problem :eek:
 
There's a nuton outside of Transfer box with a locking plate behind it. Intermediate shaft retainer I think. I can wiggle it with me hand??
 
plate stops intermediate shaft rotating ,intermediate bearings could have failed they would effect low and high gears on diff too,usual cause for input without bearing failure is poor lube ,worth dropping sump plate off new box and checking freeplay in input and intermediate gears ,intermediate can be adjusted by tightening outer nut with 3omm socket and long bar just enough to remove freeplay ,a lot of boxes have some
 
Even with the input gear assembly removed it's still jamming up when I turn the output flanges..
 
if I can interject?

Million dollar Q, James - whats the likelyhood of the main gearbox being damaged?
 

Similar threads