gearbox

Thanks Russ

Heres some info

My steering box is ok so far

You wanted post and i am glad to write it up. It is true proper engineering and is simple really if you can do such stuff

Now i have changed my server to google i can now post without my cursor going back to top of page. Many pc whizzes looked but could not sort it. Shit luck really and no help on here what to do. Its g wagon s not pc ;o; lol

Even bodging and codging would get the desired result with good reliability and a way better gearchange, even though it suffers a slightly lower 6th gear ratio than a 5 speeder

Here goes

I had a strange noise when shutting off gently from cruising speed

I thought transfer box which i had rebuilt about 20k ago

I then thought gearbox or front axle

At nearly 200k my axle needed doing after doing jasons axle i could see what needed or was possibly needed

I had a rumble rumble noise that was worse when vehicle was first driven, ie cold oils etc

Over xmas holiday i spent every day under g wagon. Bonus was it rained almost every day so i was not happy but when it proper poured down i was glad to be in shed

Right then

Stripped front axle and one wheel bearing race was totally shot. Never seen one so bad for a long time. It could not of been at top or bottom of hub as it would of made a proper loud noise when driving

Anyway did all axle and only one cv boot was split. Not bad for 200k and it had never been apart before. You can just tell as bolts were solid etc etc

Removed gearbox and gave it a quick check. I spun the input shaft in my fingers and it made a horrible dry sounding noise as if it had no oil in box. Shoot me down i never checked oil ever since i owned the g wagon as no leaks at all

Doing a project big hp diesel 190 merc and box on floor. Spun shaft the same and it was silent

6 speed box coming on as i stripped old box and 2 odd sized bearings were 180 quid

6 Speed box was 140 delivered with frame and linkage

 Fitting box i found another frame and gear linkage in the corner of my pit. Cant recall where or what it was from. If the owner had no gears im sure i would of known. All i can think is an amg clk 430 i converted to a manual and it was spare

Right the nitty gritty

To say the least a proper palava . I wish to say it in coal miners terms but i will refrain

This all sounds more work than it is

I obtained a mercedes sprinter flywheel to remove dual mass one. Mine was dual mass and mercedes brand new 3000 miles ago for 890 with clutch and bearing. Its for sale cheap if anyone needs it as new but fitted briefly

Took flywheel to work many times and modified. Flywheel had done about 175 miles in round trips and had not even been fitted yet. Happy days 

Flywheel fitted and all sorted and clutch pressure plate and clutch working spot on, could not ask for better. Proper old skool driver clutch thats smooth

Fitted cheap 6 speed box. Easy just bolts straight up. Problems are gearbox mount needs re fabricating and i had to do away with the auxillary cable assist. Less parts the better. I made a linkage and it was fine. Tried it with auxillary cable and it was precise but i just wanted it basic and nothing to let me down

I ummed and arred about cutting a snap on tools uj . It worked  at a cost of 40 quid

Made an adaptor plate so i would keep g wagon floor pan as standard if i ever chose to revert back to standard. Anal or what

Drove g wagon and it was all good. Gearchange was so much better and car was super smooth. Still had noise when easing off accelerator?????

Gearbox was the cheapest i could find for a test and from 1st to2nd it crunched a bit. Its waiting for a rebuild

It had forecast rain for the weekend so more activity in the shed

Got a 220 cdi box with 1 linkage off a 2011 car and all linkage and a nice leather gaitor and gearknob

​It was totally different. Made some adaptor plates at weekend and got one of our top machine operators to store all hole centres of gearboxes on the cnc. I dont do electronics but all info is on a stick saved 

This weekend i thought i would fit a 20k mile gearbox i bought again 6 speed. I did not reallise it was from a rare mercedes and it was in line to bell housing which is off set on most all  mercedes

​It was going  on g wagon regardless due to miles

Box was canted to one side so i had to bodge gearbox mount i had beautifully crafted for old 6 speed. I kept it so i could revert back easily. Had to jack car to obtain full oil level due to box leaning over

The linkage was staring me in the face in my garage. I pondered and thought that will work. I have heard of 6 speeds dropping out of gear. My old box did once over the railway crossings at speed. Tested my new design and all good and never jumped out of gear no matter what i did. sorted i think and with no tie to box

Gearchange is short and so slick its untrue. Proper nice and a short shift. Did i say how good t was??? I wont be going back to 5 speed and will suffer a few revs in top gear for this

Transfer box checks i will continue tomo

​Why i did not trust what i did i will never know. Much work for nothing but its funny to read. Not funny at the time, i was about to give up and buy a land rover series 2

Only kidding been there done that once and once only

                                               G