LT95 jumping out low range (at the worst possible moments)

Thanks JC, I have removed the shaft from my spare box and will use the intermediate gear from that. Its a Suffix 'B' box, the one currently fitted is a Suffix 'C'; hopefully the relevant bits are interchangeable...

Thanks to everyone for the help and tips - I have now replaced the intermediate shaft, intermediate gear assembly and needle rollers with good used parts along with new bronze thrust washers.

It ended up being easier than I expected - took a couple of evenings and my wife was able to provide the extra pair of hands when needed.

It no longer jumps out of low range, the gearbox/transfer is virtually silent:eek: and I'm sure the backlash is reduced.:)

Well worth the effort.

I changed a mates over the other week and used a piece of 40mm electrical corrigated conduit for the dummy shaft, it worked quite well:)

I recall seeing at various shows a demonstration of a lubricant additive which involved using a torque wrench and a lever to load a spinning shaft - the test involving the additive and not just plain oil resulted in the ability to apply a lot more force to the shaft before it started to smoke/squeal etc.

I seem to recall reading somewhere that chlorine may have been the 'magic' ingredient. Apparently it has the ability to improve the properties of oil in some high load applications, but not generally the ones found in an engine, as the salesperson would have you assume from the demonstration...

I cant help thinking that something like this might provide more protection to the thrust washers, (I now find myself thinking of them every time I put my foot down!). Am currently using 500ml of Moreys in the x/fer along with 15/40 engine oil.

put a shot of the hub "oneshot grease" in with the next oil change...

Dave is that some trade secret or a flippant suggestion in passing ??
Duane

So the box in my County is doing this or at least something very similar

Seems to very occasionally jump out of low into neutral only seems to happen when it's loaded right up.

Only happened twice but it's not much fun.

I'm wondering what kind of lifespan I have left on the box and what I should be doing about it. I was thinking about making something up to hold the lever in low for when I think there might be an issue.

I've made sure the leaver isn't fouling on anything but I haven't done any further inspection than that.

Jumping out of gear when under load normally means it was not locked in properly in the first case - when moved into low range after a moment or so pull the lever back/forward (as relevant) to make sure it is in, if no joy look to linkage adjustment then if no joy the selectors may need adjustment - open the top of the tfr case and adjust - a relatively easy job.

I had the same issue as you and a tweak of the selectors fixed it. Easy on a 101 as the floor lifts up maybe not so easy on another vehicle.

Garry