need help asap!! gearbox-trans case

[sikhabib]

hi guys
i have just finished pulling out the gearbox on my nm pajero to replace the clutch and want to split the trans case and gearbox to check the splines cause i have alot of backlash in the drive train.

I cant figure out where to split it





do i split at the join closest to the breather tube or the join closes to the gearstick pannel i removed?

thanks

[sikhabib]

got it all seperated but wish i didnt

the splines on the gearbox output shaft are just about to round off and the transfer box splines dont look to hot either

has anyone replaced both shafts? roughly how much am i looking at?

[Phil]

I think it would be cheaper and faster to get a 2nd hand box.

[psproule]

That very problem cost me a gearbox in the NM. I have heard of a couple of other local ones actually wearing the splines right off loosing drive completely. They were all quite rusty and dry, with bits of the splines falling off when separated. Theory is the AC drain tube positioning didn't help, along with moderate to heavy towing loads on the vehicles involved. Some were autos, some manuals.

5 speed manual plus a transfer from a wreck cost me $2200, just to purchase. But swapping the input shaft was going to cost similar and I had other issues with the transfer anyway. The 5 speed manuals are very hard to find and come at a premium. Autos were very common. Be careful as the auto and manual transfer cases have quite a few differences. We tried a swap but couldnt.

www.findapart.com.au would be a good place to start.

[sikhabib]

That very problem cost me a gearbox in the NM. I have heard of a couple of other local ones actually wearing the splines right off loosing drive completely. They were all quite rusty and dry, with bits of the splines falling off when separated. Theory is the AC drain tube positioning didn't help, along with moderate to heavy towing loads on the vehicles involved. Some were autos, some manuals.

5 speed manual plus a transfer from a wreck cost me $2200, just to purchase. But swapping the input shaft was going to cost similar and I had other issues with the transfer anyway. The 5 speed manuals are very hard to find and come at a premium. Autos were very common. Be careful as the auto and manual transfer cases have quite a few differences. We tried a swap but couldnt.
www.findapart.com.au would be a good place to start.

i was hoping you would chime in psp i did a search and found youve had the same problem. As you know finding a manual v5m31 pajero gearbox is near impossible! I called every wrecker i could find on the net and yellow pages but no one had or could find me one (plenty of auto ones around ).
I then tried that findapart website (thanks btw ) and found a guy in vic who could import me a complete geabox (inc transfer) from japan with 80,000km for $1850 + $200 delivery to sydney but he couldnt garantee the box would be in 100% perfect conditon with no noises, oil leaks, broken syncos etc.
As im doing this myself at home on car ramps i didnt want to take a chance on a 2nd hand box so i striped my box fully down and pulled out the main output shaft. I took it down to "The gearbox factory" at riversby and they were able to fix the spines on the shaft and make them better then new for $145 (better than $550 trade price for a new main shaft from MM)

My transfer input shaft was also worn so a new one from MM was $400 and a new reverse gear syncro for $45, everything else in the box was in excellent condition. Im in the process of putting everyting back together now so hopefully the car should be back on the road soon.
So far the job has been pretty straight forward, the transfer input shaft was a breeze to take out as its only a short shaft and comes out with the transfers front cover. The main shaft (gbox output shaft) was a absolute bitch as pretty much every bearing and gear needs to come off to get the shaft out and ready for machining.

A couple of pics......

complete gearbox+transfer as removed from car


gearbox


transfer box


inside of gbox


transfer input shaft


main shaft (finally out of the box )and transfer input together



this is the badly worn connection that was probably 10,000km away from sheering both splines off completely

[psproule]

Thanks for posting the pics and the info on a repair. I didn't know they were able to repair splines that fine and at such a good price. For such a big & heavy transmission it's surprising to see these splines go in such a way. Perhaps it is more prevalent in the manuals due to the shuttling on and off load and the engine braking load. I ended up taking mine to a transmission "specialist" and he didn't want to even think about swapping out the output shaft, telling me the parts alone were $1800. I'm guessing they just didn't want to do it.

Findapart has been very handy for me in the past and has come up trumps when all else has failed.

Cheers - Pat

[SilverGhost]

Sikhabib,

GOing to all that trouble stripping down the t/c, why not consider lowering the ratio at the same time. The input gear is replaced in the process, so I guess you have already spent the money on repairing that one. Contact Mark Hardman of Hardman Brothers in Melb if you are interested.

By the way, we must be close if you used Revesby Gearbox co

[mumfy]

What about trying a machine shop with gear hobbing machines, you 'may' get the parts for a lot less than a replacement box


Darren

[sikhabib]

thanks for all the input guys, just an update

the jero is back on the road and driving beautifully with the new clutch and repaired gbox. 100% of the drivetrain knocking is gone

Silvergost - i wish i read ur post before buying the input shaft cause i didnt even think of getting different ratios. Having said that our NM bearly goes off road and the few times it has the stock ratio was fine. I live at hornsby but i didnt mine the hour drive to riversby to save $400

mumfy - thats what i did with the main shaft, the gbox factory welds up the main shaft spines with stainless steel and then put it on the layth and grind the spines back on. Apparently using the stainless steel makes the spines stronger than factory. As the tb input shaft is a female spine they arnt able to repair it cause they cant weld it up properly and their cutting machine wont do it.

If i had to do it again i would in a second, total cost to repair gbox was $650 (inc oil) and i know its going to be ok for a long long time as all parts are in perfect condition. I saved a heap of money and I accutally had alot of fun doing it maybe i need to get out more lol

[trodelphin]

Hey Mate know this is an old post so i hope your still active.
Going through the same PITA problem as well and also sent today it off to "Gearbox Factory" in Sydney.
Just curious to know how it held up after time ?
A lot of the engineers i spoke to here over in WA were quite opposed to welding and recutting.

[Lance]

sikhabib was last active here 5yr ago.

If you go in to his Profile you may be able to send him a PM or email.