IIA Transmission Problem.

[TDLightweight]

Hi Everyone,

As those of you who made it to Don's place on Thursday know I had a little transmission mishap on my way in the Lightweight and turned up in a diesel Toyota van instead.

Having conducted some test yesterday with the Truck I can now report the symptoms, what I think may be the problem and how I plan to tackle them.

History.

My transmission has 5000Km on it. It is a D-series spec IIA box with a "B"series transfer case. The transmission was rebuilt by Peter Hurst who has unfortunately been seriously incapacitated by an illness.

The transfer box casing had a crack on the rear cover driver's side stud which was not an issue when I first ran the truck, but became and issue when I installed the Roverdrive.

In the fall of 2008 I rebuilt the transfer case into a new casing and also put some new seals on the clutch throwout assembly. I tried to bring the truck to the 2009 and Founders day and discovered that the transfer case was making a growling noise on the over run and parked the truck having lost my shop space.

Deciding that the issue (after much research) was probably the shims on the intermediate shaft, I gingerly drove the truck to this year's Vandusen ABFM (choosing non Hwy roads and not using the overdrive). Apart from the Over run noise there were no issues.

Anyway I tried o bring the truck out to Don's on Thursday and ran into the following issues.

Symptoms

1) With Clutch disengaged there is a tapping noise from the bellhousing area or transmission area. goes away when the clutch is engaged.

2) First and reverse can be impossible to disengage if the truck is not "rolling"

3) Reverse gear lever is vibrating

4) Truck is growling on the move

What I think may be wrong

1) Main shaft nut has come loose allowing for slop in the gear set.

2) Flywheel has come loose or clutch cover has come loose.

3) Clutch throwout assembly is binding, possibly broken connection collars on between slave and throwout assembly.

What I plan to check and do.

1) Drain gearbox oil and explore with a magnet

2) Check main shaft rear nut

3) Check throwout collars

4) Pull Transmission and check clutch and flywheel.

In Conclusion

Apart from the noise the clutch and transmission is shifting great and everything works well.

If anyone has any other ideas please let me know.

[Roverworks]

Know way of diagnosing without actually hearing the noises myself but you are heading in the right direction… You may find a damaged primary pinion spigot bearing between the primary pinion and front end of mainshaft, loose front layshaft nut and/or damaged 1st gear layshaft . Your inability to shift easily out of first is likely clutch related given there is no internal damage as above; alternatively, the nose of the primary pinion is “dragging on” in the flywheel bushing. Endless possibilities ….

Alan Simpson
Rover Works BC Ltd

[TDLightweight]

Thanks Alan,

I haven't looked it over yet but I will have ago this weekend. I will check oil level and rear mainshaft, clutch slave linkages, and intermediate gear first and then possibly pull the gearbox back to inspect the clutch and pinion bearings. The gearlever goes in without any trouble it just won't disengage easily which is why I believe the issue to be a binding fork. But the pinion bearing could certainly account for the noise too.

[TDLightweight]

Did some more troubleshooting today. I didn't start dismantling as I am feeling pretty sore today. I have Chrohn's disease and have a pretty bad weekend as far as that goes.javascript:emoticon(':sad3:')

Anyway as far as the transmission is concerned I have isolated the following.


First off I dumped in a 750ml of oil in the gearbox it was low. I had made a dipstick/filler arrangement and it is really easy to top up from inside the cab.

Clutch in everything is quiet, Clutch out and there is a loud tapping noise coming from the Bellhousing area that comes and goes . I suspect the pinion bearing cage has disintegrated. I can't think of anything else that could make that amount of racket.

I put the transfer gear knob into neutral and played with the different gears.

In addition to the tapping noise 4th gear makes a mechanical tinkling noise as well. It is apparent in 3rd as well but to a much lesser extent. I suspect the main shaft nut may have backed off and I am hearing the lock plate as the shaft whirls around.

I did not try engaging or disengaging the overdrive lest I damage anything due to the main shaft coming undone.

At this point as soon as I am up to it I will pull the overdrive and then everything else. I wasn't looking to rebuild my transmission this summer...oh well. At least my transfer case rebuild seem's o.k.javascript:emoticon(':)')



:arrow: :sad3: :arrow:

[TDLightweight]

Hi Everyone

So I am now being held up trying to remove the handbrake drum assembly so that I can remove the intermediate shaft form transfer case. the handbrake has always worked well and I have backed off the adjuster quite a bit and removed the Whitworth drum nuts. But cannot remove the brake assembly.

- Does the adjuster need to be backed out completely?

- Is it possible that the shoes are caught in a groove stopping the drum from coming off?

- There are two holes on the drum where one could thread a a bolt through to push the drum off. However these are not threaded so this idea is a no go unless I can tap the holes.

- The last time that I had to remove the transfer case I just simply removed the Speedo housing. I would prefer to do this the correct way this time though.

Any ideas?

[TDLightweight]

Ahh I forgot to remove the center nut. easy peasy after that. javascript:emoticon(':oops:')