Separating Gearbox from Transfer Case - TD5 Defender R380

[TeamFA]

G'day all!

I have the gearbox and transfer case on the floor in the garage, on my way to diagnosing a probable layshaft failure (loss of 5th and reverse gear).

I have removed all the nuts and bolts holding the two together, and now trying to separate them from each other. They're proving reluctant to part ways.

I've had a good go around with a rubber mallet, and a hammer with a block of wood, but unable to crack the seal.

Any advice on how to separate them?

Any help appreciated!

Cheers!
Michael.

http://www.aulro.com/afvb/attachment.php?attachmentid=48771&d=1341640934

http://www.aulro.com/afvb/attachment.php?attachmentid=48772&d=1341641143

[Blknight.aus]

take the inspection plate off of the Tcase and then remove the input gear.

Bet the splines in that have let go and thats whats holding up the show.

[langy]

If, after doing what Mr BK said, and it's still stuck on the locating pins, take out the big screwdriver and look for a spot on the join where you can get leverage. I've recently finished playing with a R380/LT230 that was stuck, and that's how I separated them. It helps if the assembly is laying flat without the handbrake drum.

[TeamFA]

Thanks guys, will give that a go in the morning.

Dave, is this something you've come across before?

Time for a scotch!

[Blknight.aus]

yep, some people also miss the landrover compulsory secret hidden bolt you kick yourself for not finding earlier.

Others get caught with "jeeze, I didnt know sealastic could take that much force? did I really need the bolts?"

[TeamFA]

Wouldn't you know it... came out this morning, cast an eye over the join, and spotted a hairline crack where there wasn't one yesterday. I did spray some penetrating oil along the seam yesterday, and perhaps that with the way it stood last night... a gentle twitch with a screwdriver popped it off. Phew!

Thanks for your help, guys!
Michael