More Gearbox Juju
Spring Clip In, High Gear Out!
Surprisingly, the spring-clip that popped out of Maggie's synchronizer was not listed in any catalog. I came close to just leaving it out, but David Gage of The Thatched Roof Garage insisted he send me a couple.
David had his friend Leslie remove the clips from a junk transmission, and placed them in the mail. When they arrived, it became a challenge. I looked around for any tool to assist in installation.
I had access to specialized jet aircraft tools, and surgical equipment. Surprisingly, however, the tool that I ended up using was a pair of Rapala eight and a half inch fishing pliers. These pliers have a hooked tip that assists in placement. The rest of the job became an exercise in patience and determining the best placement of the synchronizer for installation. On the third try, the spring-clip slipped in, and locked. I reinstalled the shifting forks, and buttoned everything up. Miller Time!
I found out why Maggie was popping out of high range when I completely lost high range on her. I pulled the coverplate off the transfer case, and found the high gear wheel, part# 218243 chewed up on the locking dogs. Since I was on vacation, and trying to get this job accomplished with a deadline, I called Rover's North for parts. I ordered the high gear wheel, the low gear wheel, which interlocks with it, the oil seal, and sundry fixings. Unfortunately, the high gear wheel was not in stock, and I would have to wait.Then inspiration struck. I called David at The Thatched Roof Garage and inquired.
Sure, he had a used high gear wheel, and the low gear wheel as well. We joked about the parts not being used, but work hardened, and David agreed to pull the gears and send them.
Later, on closer inspection, I realized that someone had been in the transfer case before me. Nails in place of cotter pins is a dead giveaway. I called David back. Because of the likelihood of parts being missing, David agreed to just pull the whole output shaft and overnight it to me. He gave me a screaming deal that no other place could touch. A deal so good I won't mention it here. Now THAT, friends, is a good reason to support your independent parts suppliers.
While I was waiting on parts from David, I broke out the Green Bible and began to disassemble. At each step I found evidence of Boudreaux's Fish Cleaning, Taxidermy and Transmission Service. I pretty much followed the Green Bible until I got to the step that directed me to beat out the forward bearing race with a mallet and the gearset (C1-8 Step 5). I tried, but was getting nowhere. I finally broke out a puller and the race came out like pudding. I suppose that is indicative of Land Rover's own BFH approach.
Once the bearings were out, I padded the bores with towels while I went after the snap ring to release the gears. Boudreaux had been here too. The snap ring eyes were broken. It took me over an hour to get that bastard off. If I ever see Boudreaux, he will eat that snap ring. I began to recall a few months back when I had Maggie up on jackstands checking the transmission. If I had known then what I know now, would I have continued?...... Ah well, I didn't know, today is another day, and this is supposed to be fun, right?
Once I had the gearset out, I could see the inner surface of the low gear wheel.
It would need replacement as well as the high gear wheel.
The next morning, the gearset from David arrived. True overnight service! I found myself measuring endfloat. Everything met the specs, so I disassembled it, washed everything and slid underneath to install.
The only weapon I had at my disposal was blind luck and a vast array of invectives. The spring loaded shafts and the close quarters and tolerances stacked the deck against me. Thankfully the children were asleep. The hearty supply of expletives hung in the air of my shop like cheap perfume in a funeral parlor, not really doing much good, but making everyone feel better. At last, 14 busted knuckles later, as the sun began to pinken the morning sky, and I was contemplating a 2WD Land Rover, I was amazed to have the housing slide into place. I looked at it. I blinked in disbelief. I grabbed a pair of vise-grips and snapped them on one of the studs before the housing could pop back off. I installed a few nuts, operated the selector shafts, and found everything in order.I went into the house to find my family waking up, so I made some coffee, and pondered the reassembly enjoyment still ahead.
Once back together, Maggie's gearbox performed flawlessly.
They are not a how to guide on vehicle maintenance or restoration. Reckless experimentation with gearboxes can become expensive. Don't play around if your Rover is your daily driver. Get expert advice, even if you decide to dive in. The Green Bible is indespensible But friends who know what they are doing will kick a manual's ass every time. For more of this legal CYA stuff, click here. |
[ Rover Assessment ] [ Steering Straight ]
[ Minimal Wiring ] [ Worth $500? ] [ Fuel Supply ]
[ Idle Thoughts ] [ Tough Decisions ] [ Spinning Wheels ]
[ Stripping Down ] [ The Bulkhead ] [ The Bulkhead 2 ]
[ Maggie's Motor ] [ Chassis Prep ] [ POR15 & Parabolics ]
[ Synergy ] [ The Breakfast ] [ Waking the Neighbors ]
[ A New Look ] [ Test Drive! ] [ Designing Woman ]
[ Mystery Solved ] [ More Juju ] [ Whoa Maggie! ]
[ Finish Line! ] [ Epilogue ]
[ Due Thank Yous ]
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