Thread: S3 Transfer case, Help Needed!

Are you 100% sure it's not a landie gear? sounds strange as it would be heaps easier to mod the shaft to suit the original gear rather than tool up to make a custom gear. PICS of the gear and shaft would be good.

Originally Posted by crossy

Are you 100% sure it's not a landie gear? sounds strange as it would be heaps easier to mod the shaft to suit the original gear rather than tool up to make a custom gear. PICS of the gear and shaft would be good.

yes, or it may be a modified Landrover gear - I imagine the Isuzu engine has a larger diameter shaft, and it could have the centre of the gear remachined to fit. The people who do the high ratio conversion for Series boxes is a likely candidate for someone who could make the gear or modify a standard one.
Someone here should be able to give you their name.
John

it would be a cheapish option to get a series gear broached to fit the isuzu shaft if the shaft is bigger than the major diam of the landie splines. should be around $200 - $300 for anealing, turning, broaching and re-case hardening.

the gear in definatly not a modified landy gear, i have already looked into that.

here are some photos of the very unusual layout of the Isuzu output shaft and input gear

photos are taken from the top inspection pannel of the T-Case.

The Isuzu output shaft without gear.


The output shaft with gear, spacer, shaft extension, bearing and T case rear cover plate


This is a layout of the gear and output shaft components.

The gear slides onto the spline of the isuzu output shaft, followed by a spacer. A shaft extension is screwed onto the end of the output shaft which locks onto the thread with two grub screws. the rear cover plate of the T-Case has a bearing pressed into it which locates onto the end of the shaft extension when it is mounted on the T-case

Originally Posted by paulthepilot_5

the gear in definatly not a modified landy gear, i have already looked into that.

Looking at your pictures, the damaged gear looks like a modified standard gear - as far as I can see it has had the centre turned out (removing the PTO dog) and a new spline machined to fit the larger shaft on the Isuzu box. It has then had the rear cover modified to take a larger bearing, and the special nut and spacer made to match.

John

The diameter of the gear is about 10mm greater than a landy gear, so the gear ratios in the T-Case must have also been changed

Originally Posted by paulthepilot_5

The diameter of the gear is about 10mm greater than a landy gear, so the gear ratios in the T-Case must have also been changed

Hmmm - interesting! If this is the case, then either the gearbox mainshaft is not in the same position as the original (and the end plate looks as if the shaft is in the original position) or the intermediate gear has been changed or its position moved. This does suggest that a talk to the firm that does the high ratio boxes would be worthwhile, as this is the sort of thing they do, and it is possible they modified that box. Could it be a modification of the standard output (high) gear with the intermediate shaft position moved? (and a standard output gear).

John

This link may be of some help if nothing else comes up.

http://www.hardmanbros.com.au/