Thread: Lt 95 gearbox problem HELP!

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.

Originally Posted by 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)

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.

Originally Posted by Phil B

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.

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.

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

Originally Posted by 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

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.

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.

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.