Lt 95 gearbox problem HELP!

[Blue sweden]

Hi there! Sweden calling. Short story:
I tried to put back the mainshaft transfer gear after removing my fairey overdrive, but its impossible to get the shim and the snap ring on. Whats wrong? Can i fix this without disassembling the gearbox totally? Kindly regards karl.
The floor is removed. (Range rover 1977)

[101 Ron]

I know that the gearbox should be in second gear if playing with the overdrive.
If it was not in second gear there is a chance that something moves out of place.
Someone else may know more.

[Phil B]

Hi there! Sweden calling. Short story:
I tried to put back the mainshaft transfer gear after removing my fairey overdrive, but its impossible to get the shim and the snap ring on. Whats wrong? Can i fix this without disassembling the gearbox totally? Kindly regards karl.
The floor is removed. (Range rover 1977)

I'm sure Aulro's resident LT95 expert (AKA "Bearman") will be along soon....
If not send him a PM.
I thought it was 3rd gear but I'm probably mistaken.
Good luck.

[Blue sweden]

I'm sure Aulro's resident LT95 expert (AKA "Bearman") will be along soon....
If not send him a PM.
I thought it was 3rd gear but I'm probably mistaken.
Good luck.

Hi there again. The mainshaft is stuck i can't move it forward or backwards. And now its difficult to put it in 1st gear. To make it clear, the overdrive is removed and i will put the gearbox back to original specification.
I have the original mainshaft transfer gear.

[Homestar]

As mentioned I think somethings moved - when I did my OD I followed the advice alreday given and had it in second or third? before starting.

Bearman should be along soon, he'll know for sure.

[Bearman]

G'day blue sweden. Mate you have a problem that may be an easy or a hard fix. What you should have done is place the gearbox in 3rd gear before pulling the gear off the mainshaft. What happens if you don't do this is the mainshaft is able to move a little forward when you try to put the distance sleeve and transfer gear back onto the shaft. When this happens there is a thin thrust bearing behind 1st gear on the rear of the mainshaft that falls off the lip it is on and this stops you getting the shim and snap ring back on. Most times you can get it back on by rotating the mainshaft with your hand and pushing/pulling at the same time. Try rotating the shaft 180 degrees and push / pull the shaft. You might have to do this many times or only a few before the bearing falls back into place. You will feel it when the shaft moves backward. Patience is paramount for this exercise I might add!!!! I have been known to spend a couple of hours doing this before success but the alternate of dropping and stripping the gearbox to fix it is a good incentive to have patience and persevere with it. Good luck and let us know how you go................Brian

[Blue sweden]

G'day blue sweden. Mate you have a problem that may be an easy or a hard fix. What you should have done is place the gearbox in 3rd gear before pulling the gear off the mainshaft. What happens if you don't do this is the mainshaft is able to move a little forward when you try to put the distance sleeve and transfer gear back onto the shaft. When this happens there is a thin thrust bearing behind 1st gear on the rear of the mainshaft that falls off the lip it is on and this stops you getting the shim and snap ring back on. Most times you can get it back on by rotating the mainshaft with your hand and pushing/pulling at the same time. Try rotating the shaft 180 degrees and push / pull the shaft. You might have to do this many times or only a few before the bearing falls back into place. You will feel it when the shaft moves backward. Patience is paramount for this exercise I might add!!!! I have been known to spend a couple of hours doing this before success but the alternate of dropping and stripping the gearbox to fix it is a good incentive to have patience and persevere with it. Good luck and let us know how you go................Brian

Thank you so much bearman!
Do i have to put it in some gears before i try to pull the mainshaft backward and forwards? Karl.

[Bearman]

Leave it in neutral until you get it back in place Karl and then put it in 3rd gear before you try to fit the sleeve, gear and shims etc.

[Bearman]

And don't forget to loctite the sleeve and gear onto the shaft when you do it otherwise you will have oil transfer from the transfer case into the gearbox and the output gear will wear on the mainshaft splines.

[101RRS]

Also when doing this work - make sure you tie on some sewing thread onto the circlip when playing around with it - the last thing you want is it falling down into the transfer case.

[Meccles]

Can I buy the fairy overdrive[emoji3]?

[Blue sweden]

And don't forget to loctite the sleeve and gear onto the shaft when you do it otherwise you will have oil transfer from the transfer case into the gearbox and the output gear will wear on the mainshaft splines.

Hmm im not sure what you mean exactly, do i have to put some loctite/sealant on the outer face of the sleeve that goes into det oil seal? Then i put som loctite/sealant to the splines that holding the transfer gear? .. karl.

[Bearman]

Hmm im not sure what you mean exactly, do i have to put some loctite/sealant on the outer face of the sleeve that goes into det oil seal? Then i put som loctite/sealant to the splines that holding the transfer gear? .. karl.

Yes Karl. That is sort of correct. Loctite under the sleeve where it sits on the mainshaft and on the splines of the gear and mainshaft.

[Blue sweden]

Yes Karl. That is sort of correct. Loctite under the sleeve where it sits on the mainshaft and on the splines of the gear and mainshaft.

Hi again mate☺. If i understand you correctly , do i have to put sealant inside the sleeve too? But the mainshaft is rotating and the sleeve is not. or is it another sleeve that i can not see? .. karl

[Bearman]

Hi again mate☺. If i understand you correctly , do i have to put sealant inside the sleeve too? But the mainshaft is rotating and the sleeve is not. or is it another sleeve that i can not see? .. karl

Yes Karl, under the sleeve - it must rotate with the mainshaft or it will leak oil into the gearbox.

[Blue sweden]

Yes Karl, under the sleeve - it must rotate with the mainshaft or it will leak oil into the gearbox.

Ahaaa! Thank you bearman. now i understand😀. I tried yesterday to pull and push and rotate the mainshaft without any progress. 2 hours of hard work. I will try today too. ..karl.

[Bearman]

Try pulling on it, rotate 180 degrees while holding the pressure on it and then let it move forward a little.

[Blue sweden]

Try pulling on it, rotate 180 degrees while holding the pressure on it and then let it move forward a little.

Ok. Will try that. Thanks bearman.

[Homestar]

You're not holding your tongue the right way... 😁

Best of luck.

[Blue sweden]

Can I buy the fairy overdrive[emoji3]?

Na. I think i will keep it. Maybe😊

[Blue sweden]

Hello again folks☺ after a week with frustrating work to pull and push the damned mainshaft, i surrender. The gearbox will be out of the car saturday. Maybe it will be easyer to solve the problem then. I shall turn the gearbox uppsidedown 😀.

[Bearman]

Hello again folks☺ after a week with frustrating work to pull and push the damned mainshaft, i surrender. The gearbox will be out of the car saturday. Maybe it will be easyer to solve the problem then. I shall turn the gearbox uppsidedown 😀.

Bugger, sorry to hear that. It's a hell of a job to pull/refit the box and dismantle to get that thrust bearing back on the shaft position.

[Blknight.aus]

try this..

take thegear off of the shaft snig a nice tight wire tie around it and use an occy strap to pull it back.

grab an air chisel and put a brass drift in it.

turn the shaft slowly as you hit it with the air chisel..

10 minutes and 10 rotations or so usally gets it.

[Blue sweden]

try this..

take thegear off of the shaft snig a nice tight wire tie around it and use an occy strap to pull it back.

grab an air chisel and put a brass drift in it.

turn the shaft slowly as you hit it with the air chisel..

10 minutes and 10 rotations or so usally gets it.

Hello! ☺ occy strap? What's that? Shall i use the air chisel at the front of the shaft? (Clutchside) and then "hammering" the shaft backwards? Thanks for helping me. Regards karl ☺.

[Blue sweden]

Yes bearman. Im have pain in my fingers and arms after pulling and pushing😁. But tomorrow the gearbox will be out of the car. So we will see if i can fix it. Fingers crossed👍. Im so happy that you bearman and other people here trying to help me. Kindest regards from karl.

[Bearman]

Yes bearman. Im have pain in my fingers and arms after pulling and pushing😁. But tomorrow the gearbox will be out of the car. So we will see if i can fix it. Fingers crossed👍. Im so happy that you bearman and other people here trying to help me. Kindest regards from karl.

What Dave means is use an octopus or rubber strap to hold a bit of pressure backwards on the shaft as you rotate it and use an air chisel or hammer chisel on the rear of the mainshaft at the same time. Hopefully the vibration/jarring will allow the bearing to reseat itself as you turn it. Good luck Karl and hope you don't have to pull the box to fix it.

[Blue sweden]

What Dave means is use an octopus or rubber strap to hold a bit of pressure backwards on the shaft as you rotate it and use an air chisel or hammer chisel on the rear of the mainshaft at the same time. Hopefully the vibration/jarring will allow the bearing to reseat itself as you turn it. Good luck Karl and hope you don't have to pull the box to fix it.

Ahaa! Ok. I presume that i use the chisel at the front end mainshaft?( clutchside).the gearbox is now out!👍😥 .

[Bearman]

Ahaa! Ok. I presume that i use the chisel at the front end mainshaft?( clutchside).the gearbox is now out!👍😥 .

No Karl, the rear of the mainshaft. Still worth a try even if you have it out.

[Blue sweden]

No Karl, the rear of the mainshaft. Still worth a try even if you have it out.

Aah😊 ok. Seems little strange to put some force with an airchisel to hammering it forward again. I will use some strap to hold it backwards during the hammering as you said. 👍. Lucky enough i have great patience😁 thanks again.

[Blknight.aus]

Hello! ☺ occy strap? What's that? Shall i use the air chisel at the front of the shaft? (Clutchside) and then "hammering" the shaft backwards? Thanks for helping me. Regards karl ☺.

usuing the airchisel gets you about a squillienty movements a minute, the rubber strap hold the shaft backwards (which is the direction you want it to be going in) the air chisel drives the shaft forwards just a fraction so as you turn it and vibrate it it will work the shim around in a semi random fashion.

if youve got on a micro orbital sander will do a similar thing in providing the vibration that lets the shim "wander"

[Blue sweden]

usuing the airchisel gets you about a squillienty movements a minute, the rubber strap hold the shaft backwards (which is the direction you want it to be going in) the air chisel drives the shaft forwards just a fraction so as you turn it and vibrate it it will work the shim around in a semi random fashion.

if youve got on a micro orbital sander will do a similar thing in providing the vibration that lets the shim "wander"

Ok!☺ i will try this . Hope it will work👍
Thanks again for all help. .. karl.

[Bearman]

Aah😊 ok. Seems little strange to put some force with an airchisel to hammering it forward again. I will use some strap to hold it backwards during the hammering as you said. 👍. Lucky enough i have great patience😁 thanks again.

Haha yes, patience is something that is definitely needed.

[Blue sweden]

Haha yes, patience is something that is definitely needed.

😁😁😁. Home now after a few hours in the garage. I tried with an micro orbital sander and pulled the mainshaft at the same time. But no no no😈. The mainshaft still stuck.😥
Maybe its easier to put the gearbox up on the bellhousing and then try to get the mainshaft backwards. I dont want to totally dismantle the gearbox to fix this😭.

[Blue sweden]

YEEEEEEEEESSSS😃😃😁.
at last!!! The trust bearing found its right place on the mainshaft. The transfer gear and shim and snap ring is now fitted.im sooooo f... happy😃😃😃😃😃😃. Thanks alot you dearest land rover friends in australia.
Bearman you are fantastic!
Kindest regards from the norweigan who living in sweden. Karl the viking😁.

[Bearman]

YEEEEEEEEESSSS😃😃😁.
at last!!! The trust bearing found its right place on the mainshaft. The transfer gear and shim and snap ring is now fitted.im sooooo f... happy😃😃😃😃😃😃. Thanks alot you dearest land rover friends in australia.
Bearman you are fantastic!
Kindest regards from the norweigan who living in sweden. Karl the viking😁.

Yippee, well done Karl (the viking)[wink11][wink11][wink11]

[Blue sweden]

Yippee, well done Karl (the viking)[wink11][wink11][wink11]

😀😀😀👍👍. Yes bearman. Patience sir patience. 😁. Learning all the time.
Again thanks for all help. Happy karl😃

[Meccles]

Great to hear! Bearman is a legend my LT95 with his center diff is working just fine [emoji3] But could use an overdrive [emoji12]

[rar110]

The LT95 Oracle. [emoji3]