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Thread: Engine & Gearbox Issues - Time for a Work Plan

  1. #1
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    Engine & Gearbox Issues - Time for a Work Plan

    Hi All,

    The time has come when I can no longer ignore the ever increasing list of stuff that needs fixing on my County. The 4BD1T is leaking at the rear main (a new seal kit was installed a few years back but only lasted a few months) and the LT95 now jumps out of high range in reverse. It jumps out with a violent bang and usually goes into low range. The box has always leaked internally between gearbox and transfer box, and has a "balance hose" running between the fillers. I have never been able to cure the handbrake drum leak, despite numerous attempts.

    The car has a lot of other issues, such as worn tie rod ends, tatty accelerator cable, some wiring that needs tidying and a leaking hub seal. It also needs a paint job and some minor body repairs.

    If I decide to repair it, I expect it will take a few months, which means I'll have to buy another car as a daily driver. I can take the engine and box out myself, but I want someone who knows what they're doing to make the engine leak free and repair the gearbox. I'm in Brisbane and don't know of anyone who can do the work to a high standard. I would put the gearbox on a pallet and freight it somewhere for repair if necessary.

    In terms of cost, I would guess that I'm in for many thousands of dollars, especially by the time I sort out the rest of the car. I would consider buying another 110 that is in better shape, but these are not exactly easy to find.

    So, to help figure this out, does anyone know of a good mechanic or specialist who can help with the gearbox and engine issues? Or does anyone have any other helpful suggestions?

    Cheers, Dave.

  2. #2
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    Send the gearbox to bearman to sort for you. There is an isuzu wear sleve and rear main you can get from isuzu, info on it on this site

  3. #3
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    Quote Originally Posted by Vern View Post
    Send the gearbox to bearman to sort for you. There is an isuzu wear sleve and rear main you can get from isuzu, info on it on this site
    Thanks mate. We fitted the Isuzu sleeve and rear main and that's what has failed. I'm not sure I'd like to get the sleeve off to try again.

  4. #4
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    try KLR in Sydney

    Hi,
    I have no connection with KLR in Sth Windsor in Sydney but they do a lot of the Isuzu repair/refurbishment of the army ones and do a number of gearbox mods on these 4 speed boxes behind the Isuzu motors to overcome various issues--no harm in giving them a call I guess. They have a paddock full of army ones and containers of spares as well so do know what they are doing from all I have heard.
    Alan

  5. #5
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    I must agree that I have seen a turbo fit and power steer fit by KLR to a ex military RSPV?( or whatever a 110 soft top is called) , and it was very nicely done.
    The dump pipe was very beautiful.
    Regards Philip A

  6. #6
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    Another endorsement for bearman. He rebuilt an LT95A for me to replace my gearbox when it suffered a major failure. Good price, excellent service and peace of mind that the rebuild was done by someone with experience and care. Brian also shipped the new 'box to Bright, Vic via e-Go at very reasonable cost.

  7. #7
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    Thanks guys - I'm currently distracted by a bout of influenza but it looks like this will come down to our holiday plans over the next couple of years. If we decide to head out to the Simpson, up the cape and so on we can probably justify the expense. If not, we'll have to dispose of the car. I'll contact Bearman soon for a chat about the box and start looking at an overall budget.

  8. #8
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    Regarding the rear main, are you sure that's where the leak is coming from?
    If you fitted the Isuzu sleeve and the larger seal I'm really surprised it's leaking as mine has been there for years with no dramas. The front housing on the gearbox is well known as a source of leaking, and if you're running engine oil on the gearbox I'm not sure how you'd rule that out without putting a camera into the bell housing.

    Steve
    1985 County - Isuzu 4bd1 with HX30W turbo, LT95, 255/85-16 KM2's
    1988 120 with rust and potential
    1999 300tdi 130 single cab - "stock as bro"
    2003 D2a Td5 - the boss's daily drive

  9. #9
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    Quote Originally Posted by steveG View Post
    Regarding the rear main, are you sure that's where the leak is coming from?
    If you fitted the Isuzu sleeve and the larger seal I'm really surprised it's leaking as mine has been there for years with no dramas. The front housing on the gearbox is well known as a source of leaking, and if you're running engine oil on the gearbox I'm not sure how you'd rule that out without putting a camera into the bell housing.

    Steve
    Hi Steve. I can't say for certain that the front housing on the gearbox isn't also leaking, but I'm sure that at least a good portion of the oil is coming from the rear main. I've checked the colour of the oil in the box and it's relatively clean and clear. The oil coming out of the bell housing is jet black - nice and sooty just like the oil in the engine. On that basis at least a good portion of what's leaking out is coming from the engine.

    I suppose I'll fit another rear main seal kit and hope for the best. My biggest concern is how I'll get the sleeve that's currently fitted off, but Bearman thinks I can probably just lever it off. We secured it with some sort of compound, so I'm not so sure. There's a list of other things to sort if we go ahead too. First thing is to get over the flu.

  10. #10
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    If it's the Isuzu wear sleeve and larger 6bd1 seal I can't see a reason you'd need to remove the ring unless it's damaged. From memory it appeared to be a hardened sleeve so unlikely it's worn already. Should only need the seal itself.
    Does the engine get a decent workout or just toodling around town? I wonder if you've got excessive blowby/breather issues?

    Steve
    1985 County - Isuzu 4bd1 with HX30W turbo, LT95, 255/85-16 KM2's
    1988 120 with rust and potential
    1999 300tdi 130 single cab - "stock as bro"
    2003 D2a Td5 - the boss's daily drive

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