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The Gearbox Ted
Topic Started: Friday 9-04-2010, 09:11 (246 Views)
ShootingStars5
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Hi Ted

Just wondering how the repair is coming along? Hope all is going well.

Cheers
Lyn
See a Shooting Star tonight - find a nuggie tomorrow!
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Topcat
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Hi Lyn,

Managed to get the gearbox out on Wednesday & took it in for reconditioning today. (Cheaper then exchange).
I was correct with my diagnostics where the needle roller bearing on the gearbox layshaft (2nd & 3rd gear) had shot itself.
Unfortunately in the process it had damaged the layshaft as well so extra costing for new shaft.
Will get it back mid next week - so all going well will be back on the road by the end of next week.
The mechanic that is doing the job is going to beef up the fifth gear arrangement so I will not
have any problems if I want to tow in fifth gear.
It involves fitting a better designed gear & spline assembly on the output shaft for only $150.00.
All up will cost $2800 so should last the life of the vehicle as the last box did 280k.
Still might bite the bullet & get a 4500 as there looks like a new model may be out soon & prices may drop.
Will be heading back up the the Gascoyne again maybe next month as the patch I found looked very promising
& temps will be a lot cooler.
I put a pic of the area I'm looking at on the website intro.

Cheers

Ted
Cheers,

Ted


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ShootingStars5
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Hi Ted
That's good news. Fairly quick turnaround also.
Bit of a bummer with the Toyotas not being able to tow in 5th gear. We don't in ours but know another Troopy owner who tows in 5th with his. Think his Troopy has done well over 300,000kms.
A mate of ours had a 95 or 98 Troopy and his gearbox went at 180,000kms. He never towed in 5th either but have had a couple of friends say that it was a fault in those models.
Good luck with it all and hope you will soon be back working on digging up some gold nuggets!

Like the picture you have put up as well.

Cheers
Lyn
See a Shooting Star tonight - find a nuggie tomorrow!
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thedigger
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Hi Ted
It is funny how they never warn you about towing in 5th gear,a friend did 5th gear twice till they told her that not to tow in 5th gear.I have just bought a Mazda bt50 and ask them about it and they said it was like reverse gear (not strong enough)and you should not tow in it.
Regards Frank
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Topcat
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Hi Frank,

Yes towing in 5th. gear has been a problem with Tojo gearboxes due to the cross section loading area of the 5th.gear
on the output shaft spline being too small to take the load consequently eventually chews the spline out.
On the later 75 series boxes 1995 onwards ( & not the 78 or 79 series) Toyota strengthened the output shaft & the
transfer box idler shaft to take the greater loads but didn't improve on the 5th gear design itself which still does
manage to chew the spline out.
I only use 5th. gear towing when on reasonably flat areas where the gearbox is not labouring because it is technically
an overdrive gear.

Cheers

Ted
Cheers,

Ted


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www.havewheelswilltravel.iinet.net.au
"I believe that if life gives you lemons,you
should make lemonade & try to find somebody
whose life has given them vodka, & have a party"!!!!

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marty
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G-Day Fred,have you got any photos of your set-up on this site,i have a mate who is setting up his Troopy at the moment.Thanks MARTY
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Topcat
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Hi Marty,

If you mean me I have full details of my Troopy setup on my own website URL is found
at the bottom of my signature.
Just click on it to open the site.

Cheers

Ted
Cheers,

Ted


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www.havewheelswilltravel.iinet.net.au
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marty
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Thanks TED, good setup, sorry about the Fred bit. MARTY
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Topcat
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Hi Members,

Finally finished the gearbox repairs & the Troopy is back on the road.
Now to start saving for my next trip.

Cheers

Ted
Cheers,

Ted


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www.havewheelswilltravel.iinet.net.au
"I believe that if life gives you lemons,you
should make lemonade & try to find somebody
whose life has given them vodka, & have a party"!!!!

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ShootingStars5
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Great stuff Ted

Hopefully won't be too long before your next trip.

Sounds like there was a lot of work involved.

Cheers
Lyn
See a Shooting Star tonight - find a nuggie tomorrow!
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Dognug
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Good to hear TC. You dont muck around, it didn't take you long. How does it sound? Can you hear any whining in any gears?
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Topcat
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Hi Lyn,
The only thing that slowed me down was the weather!!!
It's not all that difficult to drop a gearbox & re-install.
The hardest part is lining it up with the clutch plate.
Sounds good with the radio turned up!!!!!!!!LOL
No seriously it runs now as quite as a mouse.

Cheers

Ted
Cheers,

Ted


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www.havewheelswilltravel.iinet.net.au
"I believe that if life gives you lemons,you
should make lemonade & try to find somebody
whose life has given them vodka, & have a party"!!!!

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detrackozi
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Ted

4500 funny things happening there just can't give them away at the moment a mate just got one for a exchange of a Xtreme and $3200 they are selling them now with two coils standard and 16dd


Back to Boxes yes I say mind will also need to be done soon aswell as it has a slight noise there now so open to the best way to have it done and the best thing to get done to it while it is out.

I 'am all ear's


Ted use to have that trouble with the old VW and I got a spare shaft from the wreakers and just lined up the clutch plate on the flywheel then you can just turn the gear box shaft till it slip in not sure if that would work on these big boxes.

I have 270 up on mine now and it is common on the range of troopys


David
http://detrackozi.com/ updated 27-12-2011
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Topcat
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Hi David,

I found it was cheaper to get mine reconditioned then do an exchange.
I would have reconditioned it myself but after doing a few of these jobs in the past I no longer have
the patience to do them anymore.
If you have time to spare for the vehicle to be off the road during that period then that is the way to go.
I would look for a reputable transmission dealer who deals in 4X4 transmission reconditioning.
If your box just needs the usual recon parts i.e. seals,syncro's & new bearings then it shouldn't set you back
anymore then around $1600 for parts & labour. That is if you drop & reinstall the box yourself.
Mine had the damaged shaft & that cost me extra for replacement.
The cost now for a drive-in drive-out job is around the $4 grand mark.
I recommend you go to a fully synthetic gear oil as this makes the box run a lot cooler, quieter & easier gear changes.
Also if you can afford it get the 5th gear upgraded to a combination 5th.gear/PTO gear in one integral unit.
This increases the 5th. gear spline loading area on the output shaft by 300% so if you want to tow in
5th. gear without chewing the shaft spline out then this is the way to go. It should only cost around $150 for the gear.
Check the condition of your clutch & replace if necessary.

When I mentioned having trouble lining the box up to the clutch I meant getting the lifting angle right so all
I had to do was push it forward into the clutch housing. Took me awhile to get it right doing it by myself,
but once I got it she fitted in without any trouble.

BTW I'm still looking for a 4500 so if you see one for sale at a reasonble price then PM me with the details.

Cheers

Ted
Cheers,

Ted


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www.havewheelswilltravel.iinet.net.au
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should make lemonade & try to find somebody
whose life has given them vodka, & have a party"!!!!

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Nightjar
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Hi Ted,
Once we get get sorted here, unloading, etc etc etc I'll drop in for a chin wag and see how you managed to raise and lower the gearbox on your own?
Always worries me towing in 5th gear with the Patrol, many I have met say they never use 5th, like you, I drop it in when the going is easy.
Actually the last two trips I used my dash mounted GPS to determine when I was declining. Quite often especially between Sandstone and Leinster you think the road is flat or on a slight decline but a check on the GPS elevation shows a slight uphill climb so it's 4th gear only.

Cheers

Peter
Good luck & safe travels
Peter


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