Time to say goodbye?

[Flying Torquewrench]

The universal joint on the front prop shaft is considerably bigger than the joint on the rear prop shaft. All in all an easy job to do.

 

[solarman216]

See what you mean about the box, completely different, so not much help from me then, hope all goes well, Rick

 

[Flying Torquewrench]

No problem Rick. Always good to hear other opinion.

Today I had nearly every delivery company at our house.

Only had 1 pin punch which was too big for the retainers in the gearbox. So I ordered a new set. Not the highest quality available but I hardly use them so no need to break the bank.

 

[Flying Torquewrench]

My brake line tools had seen better days and were a bit cumbersome when being used on the car. A new set of tools was completed today.

 

[Flying Torquewrench]

I also had no way of moving the gearbox off the transmission jack. If really desperate I could use my digger but this is not ideal. To make the gearbox repair a bit easier I bought a 2 tonne chain hoist and a 2 tonne girder trolley to hang it off.

Once my new building is ready I am planning on building a gantry to hang it off.

 

[Flying Torquewrench]

The steel beam the chain hoist hangs from is where two parts of the roof meet. It is roughly 5 metres in length and I don’t know how much more weight it can take. It should be able to deal with the weight of the gearbox as it should be able to hold a roof full of snow. However, better safe than sorry so I put an acrow prop under the steel beam.

 

[Flying Torquewrench]

I am out tomorrow to have a reversing camera fitted to my Volvo. The rest off the week we have nothing planned so with all the tools in place should be able to start work on the gearbox.

 

[solarman216]

I think that beam is well capable of taking the box and probably the engine as well, but I agree best take no chances, Rick

 

[Flying Torquewrench]

Started work on gearbox today. Unfortunately a little grub screw on my transmission jack sheared off. The jack has a 200kg capacity but the gerbox including transfer box is a bit too heavy for it.

 

[Flying Torquewrench]

To make it useable again, I just ground a bit of a normal bolt. Which did the job.

 

[Flying Torquewrench]

Where the gearbox connects to the engine the bell housing seemed quite wet. Even when installed on the car the weep hole was always wet. I am wondering if they replaced the front oil seal when it was overhauled in 2019. My suspicion is that they didn’t.

 

[Flying Torquewrench]

To be able to remove the casing of the gearbox the transfer box had to be removed. Where the transfer box mounts onto the gearbox, the gearbox had quite a bit of sludge in it. Ran a magnet through it and it is not magnetic, neither does it feel like particles.

I am just a bit disappointed as one would expect that when they overhauled the gearbox they would have cleaned all this.

 

[Flying Torquewrench]

Removed the casing and called it a day. Quite a few small fiddly parts to be removed before the front casing can be removed. Better leave that for tomorrow.

 

[solarman216]

That selector fork is the 3rd/4th gear, so if it is stuck in 3rd that fork and operating shaft are the ones stuck, Rick

 

[Flying Torquewrench]

As said before Rick, you have sharp eyes. The gears are stuck in 4th and not 3rd as I previously mentioned.

 

[Flying Torquewrench]

Finally finished disassembling the gearbox and I am pretty sure that I have found the problem. On the synchroniser ring there are 3 spring inserts. One of mine has been dislodged as can be seen in the photo.

First a photo if one in its correct position.

 

[Flying Torquewrench]

Now a photo of the one that is dislodged and therefore jamming the gear lever.

During on of my searches last week I came across a video describing this exact problem.

 

[Flying Torquewrench]

I pushed the insert back into place and the gearbox shift as before. There is a bit of damage to the insert where the shifter hits it all the time.

New ones can be ordered from Amayama for about £1.76 each but they have a 3 week delivery time. I haven’t spoken to the Nissan dealer yet as they seem to be able to supply them within a week but it comes at a cost. Hopefully I can replace them without disassembling the whole gearbox first.

 

[Flying Torquewrench]

For anybody interested, this is the inside of a Patrol gearbox.

 

[solarman216]

You are going to need to pull the layshaft first after that it will only be the selector fork holding it on, be careful the needle rollers 1st motion to main shaft may not be captive, I would be replacing that synchro ring as well, it looks quite worn and it is likely to be worn where it contacts the insert, if you look at your pic of the dislodged insert the ring has no clearance between it and the first motion shaft, this should not be at all, it might be that this is a fault on your style of box if you found a vid on it, worth checking with Nissan if there is an upgrade, Rick