Thread: Transfer box jumps out of low

Went out camping and 4x4ing this weekend in the SIII. Found that it loves to jump out of 2nd gear (under backlash), this I can handle; just use 1st or 3rd depending on the situation. What did scare me the other day was that coming down a moderatly steep slope it jumped out of low range! I thought that I hadn't engaged low properly BUT today it did it about 4 times in 1st, 3rd and 4th gears.

Now. Looking at my Workshop manual for SII and SIIA under the Defect location section it states:

Jumping out of low transfer:
1. Transfer selector fork assembled wrongly on shaft - Assemble with set towards rear of vehicle
2. Too much end-float on intermediate gear - Adjust
3. Selector Spring too wear - renew.

has anyone done any of this before? can you offer some advice? How hard is it to do with only basic workshop tools?

Remembering that I have a gearbox that doesnt' like 2nd and that leaks oil out of the selector shafts (I think....) I was thinking maybe I should look at getting a recon gearbox and transfer case. I'm don't have the tools to redo my own gearbox. And It also seems like a big job that just might be beyond my mecanical skills.....

If I was to get a new gearbox is it worth looking into a 5 speed? I use the car for camping, 4x4ing and is basically a go anywhere toy for me to play with rather than a restoration-sit-in-the-shed-and-look-pretty-car. IF I should start to look for a 5 speed what should I look for?

Thanks guys

If you're going to rebuild the gearbox there are some photos of the rebuild of my Series III box in this thread http://www.aulro.com/afvb/other-powe...eries-3-a.html

You could try and find a secondhand box & transfer box and rebuild that first, then you can just swap them over. The workshop manual and the Haynes manual had good sections on how to strip and rebuild a gearbox.

I spoke to someone recently who paid $2,500 to get their gearbox rebuilt so doing it yourself can save a bit of money......


Colin