Well, it certainly was good to be able to get back into the nitty gritty of working on my Stage 1... well sort of. Today I was dealing with the replacement gear box that came out of a range rover.
Since this gearbox is known to have a problem of jumping out of 2nd gear, the plan is to strip out everything from the inside and transfer all the good bits from the gearbox in the car into this casing. Anything that is damaged I will have to replace with the original bits that came out of this box.
Anyway, on with the photos.
The Range rover gearbox, from now on refered to as Gearbox 1... the one that is in the car at the moment I will call Gearbox 2. The gearbox sat for ages on the workshop floor with the covers to the transfer case open so it was all full of dust and grit, but its nothing that can't be cleaned up.
The box after I finished with pressure washing and numerous coats of degreaser.
After letting it dry for a while I removed the bell housing, only to discover the bolts of the housing also hold the input shaft bearing plate onto the gearbox, so as I didn't plan on dealing with the gearbox just yet I had to put some of the bolts back in with some spacers to hold it closed.
Next, the output shaft along with the diff lock actuator and locking dog was taken off.
The Centre diff splines that are engaged by the locking dog when the diff lock is turned on... similar to a maxi drive system it seems!
Next, the rear output shaft was to be removed. According to the manual it suggested that you could simply unbolt the flange along with the handbrake drum still attached and it would separate away easily from the centre diff and the transfer case.
When I did this, I suddently found much more bits coming out than I had expected... the centre diff decided to come along also. It isn't much fun when things don't come apart as they are indicated in the manual!
The big hole where the centre diff used to sit.
I ended up needing to pry the centre diff away from the rear output shaft, it wasn't anything difficult but you couldn't get them apart with your hands.
Something tells me that once upon a time the insides of this transfer case let go. There was all sorts of gouges on the area where the centre diff bolts were. Probably the same thing that happened to mine, although they were lucky and didn't end up with a big hole in the side with bolts poking out of it!
Next, the intermediate shaft and gears have to come out.
The manual called up using a shorter shaft which you push in after you have removed the original shaft to allow the whole lot of gears to come out as an assembly. I didn't have this so I simply held on to each gear as it disengaged the shaft as it was pulled out. A variety of shims, plates gears and needle bearings fall out when you are doing all of this so I found myself having to pay careful attention to the order that things were falling off the shaft.
Once the intermediate shaft was removed I placed all the gears back on in the order they came off to make sure it couldn't be stuffed up later.
Next I pulled off the gearbox output gear, It was held in place by a snap ring which was a pain in the arse getting off without proper snap ring pliers, but I got there in the end!
The removed gear
Next will be the gearbox, the main shaft has a spacer in the transfer case compartment which is what is used to space out the output gear in the transfer case. Acording to the manual you need a special puller to pull the spacer off the shaft. I don't have that puller so looks like I might have to get creative and make one. Will have to see when I deal with it tomorrow.
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