Thread: rr 5spd probs lotsa noise no motion

Had the same problem with the same age vehicle some 10 years ago. Turns out the transfer case was in neutral. This was caused by a problem with the H/L Range lever mechanism & a wayward detent if I remember correctly. I fixed it in place without too much trouble.

to check the gearbox output...

start the engine, in gear with the park brake on and foot off the clutch, if it doesnt try to move go on with the next bit, you will need a helper, a torch and a mirror on a stick.


drop the pto output cover, watch the input gear and have seome one else jog the starter with the coils power lead removed or for a diesel the fuel cut off wired closed so the engine wont start.

If you cant see the big gear move the gearbox is at fault, select another gear and go again.

If the big gear moves change ranges on the tcase get out from under the car and try again.

good luck

It could be several things. One of the checks is the transfer selector as advised above. It could also be a stripped outer half shaft and cv joint. That was the problem on mine. Just pull out one of the half shafts and inspect. Not a hugely difficult job, just a little time consuming. If it is this look for a good second hand half shaft and cv as new half shafts are ridiculously expensive.

Wear of the splines of the gearbox mainshaft and the mating input gear in the transfer case is a well known problem.

This has been fixed by a new input gear with longer splines and a cross drilled hole that provides better lubrication for the splines.

Unfortunately it is expensive to replace the gearbox mainshaft and t/case input gear.

WORST CASE SCENARIO

Originally Posted by Bush65

Wear of the splines of the gearbox mainshaft and the mating input gear in the transfer case is a well known problem.

This has been fixed by a new input gear with longer splines and a cross drilled hole that provides better lubrication for the splines.

Unfortunately it is expensive to replace the gearbox mainshaft and t/case input gear.

This happened to my LT77 on the Freeway @ 406,000km. The splines on the output gear and the mainshaft don't get lubricated and they eventually wear and give out. The replacement output gear is cross drilled to allow oil to get to the splines and reduce wear. The mainshaft means a gearbox rebuild.

A fellow aulro-ian gave me an LT77 that "needs bearings only" a day after I ordered $1,800 worth of parts to rebuild my LT77. I opted to rebuild the LT77, replacement boxes were $1,300 with who know how much wear, and rebuilt boxes were much more. R380s were out of my price range.

The Good News

If this is what has happened to yours, PM me if you would like to give the LT77 in my shed a good home. - That's the one that "needs bearings." Hopefully you can save the $$$$$ I couldn't.


- Michael2