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#Post#: 85323--------------------------------------------------
Series 3 gearbox strip down
By: samc88 Date: February 15, 2014, 4:16 pm
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I 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
[URL=
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[URL=
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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
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152164_zpsb5be2dc6.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152164_zpsb5be2dc6.jpg[/img][/URL]
[URL=
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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.
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152169_zps86d71adb.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152169_zps86d71adb.jpg[/img][/URL]
Revealing some gears:
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There is quite a lot of debris in there (I think this is from
when it had a period of being stored outside though)
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152171_zpsee758f95.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152171_zpsee758f95.jpg[/img][/URL]
The nut and spring washer securing the intermediate shaft was
removed using a 15mm spanner
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152172_zpsba145100.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152172_zpsba145100.jpg[/img][/URL]
To get better access I tipped the gearbox over (i.e. so the
transfer box plate would be underneath) and a nut fell out:
[URL=
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Then of course I tipped it back up revealing :eek:
[URL=
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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 :D
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152175_zps1621d70e.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152175_zps1621d70e.jpg[/img][/URL]
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.
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152176_zps0f3ae214.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152176_zps0f3ae214.jpg[/img][/URL]
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152177_zps845dec30.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152177_zps845dec30.jpg[/img][/URL]
this could then be removed allowing access to remove the backing
plate. Note there is a felt washer behind it
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152181_zps2394dcfc.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152181_zps2394dcfc.jpg[/img][/URL]
The nut, washer, felt washer and main part were cabledtied up to
keep them together :)
[URL=
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The 4 nuts and spring washers holding the back plate on were
removed with a 15mm spanner
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152185_zps0885282b.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152185_zps0885282b.jpg[/img][/URL]
[URL=
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As you can see, the shaft now has plenty of clearance to come
out :)
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152188_zps24622ae2.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152188_zps24622ae2.jpg[/img][/URL]
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152189_zpsf79675a3.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152189_zpsf79675a3.jpg[/img][/URL]
Then the intermediate gear can be rolled out of the casing
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152190_zpsc9792eca.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152190_zpsc9792eca.jpg[/img][/URL]
Inside this is a long roller bearing
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152191_zps4c77eb30.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152191_zps4c77eb30.jpg[/img][/URL]
Next the thrust washers either side of the gears in the casing
were removed
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152192_zpsae875985.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152192_zpsae875985.jpg[/img][/URL]
[URL=
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/>
Judging by the colour difference either side of each one, I'd
say they are worn? Do you agree?
[URL=
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[URL=
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/>
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:
[URL=
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Where 2 of the internal ones are, the third is behind the
mainshaft in this pic
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2152198_zps501634cc.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2152198_zps501634cc.jpg[/img][/URL]
So there we have it :) Tomorrow I'll hopefully get the boxes
split :)
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 :D If I had some
wood I would have used that :) )
#Post#: 85325--------------------------------------------------
Re: Series 3 gearbox strip down
By: divie Date: February 15, 2014, 4:51 pm
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Any folks playing around with gearboxes, remember I made a batch
of mainshaft tools. Free to loan but require a £20 deposit to
ensure they come back. Three down here with me in Kings Bromley
South Staffs and One with RMS in W.akefield. If you need it
posting post is £6
#Post#: 85326--------------------------------------------------
Re: Series 3 gearbox strip down
By: samc88 Date: February 15, 2014, 5:09 pm
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Thanks for the offer but I just use a punch on the castle nut :)
(I havent got one of them at the minute either, oh well :D
Going to see about stripping it all, assessing the condition and
seeing if I can get hold of the missing bits before rebuilding
fully. My plan is to try and get this box as a good spare so if
the one in the series fails at any time I can do a straight swap
and keep him on the road. It also satisfies my curiosity as to
what goes on in the box anyway and as I didnt pay for it I
havent lost anything in stripping it, only a bit of time :)
#Post#: 85328--------------------------------------------------
Re: Series 3 gearbox strip down
By: divie Date: February 16, 2014, 2:46 am
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A lot of people use a punch on the mainshaft, 85 lbs torque is
not easily achieved with a punch and loose nuts give problems.
That is why I made the tools, they are made from EN24T steel
like the £60 ones from Ebay.
#Post#: 85353--------------------------------------------------
Re: Series 3 gearbox strip down
By: samc88 Date: February 16, 2014, 5:12 pm
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Right then, got the boxes separated this afternoon:
[URL=
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[URL=
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[URL=
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I decided to strip the transfer box out first so put the gearbox
back on the trolley.
First task was to remove the selector plunger using a 15mm
spanner:
[URL=
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[URL=
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This is made of 3 parts, the cap, the spring and the plunger
which locates in the shaft
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2162206_zps96d79ce4.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2162206_zps96d79ce4.jpg[/img][/URL]
Then the cover plate was removed using the 7/16ths spanner
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2162207_zps7c83fad0.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2162207_zps7c83fad0.jpg[/img][/URL]
Next the pinch bolt for the forkselector was removed (apologies
for the blurry photo)
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2162209_zps029405cf.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2162209_zps029405cf.jpg[/img][/URL]
[URL=
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Then the nuts holding the output shaft housing to the transfer
box could be removed allowing the housing to be split from the
box
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2162211_zpsddf7847d.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2162211_zpsddf7847d.jpg[/img][/URL]
[URL=
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[URL=
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[URL=
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The selector fork was then removed
[URL=
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Next thing to be taken off was the speedometer housing, again
removing the nuts with a 15mm spanner
[URL=
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[URL=
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[URL=
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Here is the worm gear
[URL=
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[URL=
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With the housing are some shims (2 in this case)
[URL=
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[URL=
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These bits were then cable tied together so as not to loose
them. Next was to knock out the shaft rearwards using a mallet.
The bearing (Timken) looks pretty good :)
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2162223_zpsf2a48fdf.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2162223_zpsf2a48fdf.jpg[/img][/URL]
Then the big circlip on the front end was removed so I can
remove the bearing outer race tomorrow (was too late to start
knocking things really). Will carry on tomorrow after work :)
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2162224_zps30973ead.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2162224_zps30973ead.jpg[/img][/URL]
#Post#: 85376--------------------------------------------------
Re: Series 3 gearbox strip down
By: Lucy Date: February 17, 2014, 1:11 pm
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The thrust washers are only coated on one side.
Looks pretty manky in there.
#Post#: 85387--------------------------------------------------
Re: Series 3 gearbox strip down
By: samc88 Date: February 17, 2014, 2:48 pm
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First thing I did was to drift the bearing off the shaft (well
as far as I could). Sorry for the blurred photo of this one
[URL=
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Then I removed the circlip holding the gears on which allowed me
to withdraw the shaft out the forward bearing bore
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2172226_zps9e552a53.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2172226_zps9e552a53.jpg[/img][/URL]
[URL=
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This allowed me better access to get at the bearing race which
was a very tight fit. Knocking it didnt seem to do much so got
the arbor press out again to do it. Here it is about halfway out
[URL=
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the completely removed race
[URL=
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Leaving me with a stripped transfer case
[URL=
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The order the bits are on the shaft
[URL=
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[URL=
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Bearing outer race, inner race, circlip holding gears on and
thrust washer
[URL=
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High gear
[URL=
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[URL=
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Low gear
[URL=
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[URL=
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Shaft with bearing
[URL=
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The transfer box looks pretty good gear wise so I think I will
rebuild this at least as a good spare, the main box on the other
hand... well we shall see. (This is more an exercise in seeing
how to do one so its pretty interesting for me having never
stripped one before)
#Post#: 85427--------------------------------------------------
Re: Series 3 gearbox strip down
By: StuartN Date: February 18, 2014, 4:02 am
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Very interesting thread,
keep it coming.
S :thumbs:
#Post#: 85443--------------------------------------------------
Re: Series 3 gearbox strip down
By: Gozo_Joseph Date: February 18, 2014, 2:17 pm
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time to dig out the land rover manual and print some pages,
gearbox overhaul next on list for this summer, been trundling
about sing 2008 now there is a sharp feel of backlash/loose
things. now it is either wear in shafts, or layshaft bolt loose
or mainshaft nut loose :| but bearings need to go me thinks.
ps divie
[quote]A lot of people use a punch on the mainshaft, 85 lbs
torque is not easily achieved with a punch and loose nuts give
problems. That is why I made the tools, they are made from EN24T
steel like the £60 ones from Ebay.[/quote]
dont you happen to help me out with how you did it? or perhaps
post me one at a cost (sale) pm me i think it would be better.
there are some on ebay. are they yours?
joe
#Post#: 85446--------------------------------------------------
Re: Series 3 gearbox strip down
By: Peter de Dawg Date: February 18, 2014, 2:30 pm
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Dunno how anyone can work in rubber gloves tho ! :toothless:
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