Jumping out of Low Range in Overrun

Submitted: Friday, Jan 03, 2003 at 01:00
ThreadID: 2787 Views:1695 Replies:8 FollowUps:7
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I have an 80 Series with 300,000 klm on the clock. It has done much of this in 4x4 (there is plently of slack in the front diff, etc.) On the last couple of trips I have done, it has jumped out of low range while on very steep downhill runs.

I assume this is going to be a worn selector problem, but am I likely to be up for much more than this?

I will probably rebuild the box myself, just not been into this type of box before. Is there anything particularly special about the assembly process that Gregories manual does not say? Or is this very defunately one for the pro-shop?

Oh! And Happy New Year to you all!
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Reply By: chopper - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
my 75 does the same thing. The navigator gets the job of holding the gear lever in place. Or I drive one handed, far from the best situation but it works.
AnswerID: 10499

Follow Up By: Pip - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
Cheers Chopper

Been doing the one-handed bit, but this makes my wife even more worried! She already has both hers hands firmly clamped to the sissy bar in these situations, so no chance of getting her to hold the gear lever in place!

I am just going to have to fix it!
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FollowupID: 5527

Reply By: chopper - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
Nah, gets her more involved that way.

Seriously though, let me know how you go.
AnswerID: 10505

Reply By: johnsy - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
Pip Ive not built a gear box full stop but my brother was in the trade and has done his lux and is a perfectionist and cost a few $. He used double lipped seals on input / output shafts and had the shaft chromed for the exact tolerance where the seal ran all new bearings etc and when I asked him about how hard it was his comment was easy so long as you lay it out as it comes out and measure all your tolerances exactly.He later on got into mogs for AAT Kings so I hope that gives you the help to do it yourself then if it breaks you have a good understanding of what and where things go .I have done the complete front diff on a rangie out of a Gregories and I was a butcher at the time .( Some butchers wear aprons others wear overalls )
AnswerID: 10506

Follow Up By: Pip - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
Thanks for that johnsy

Yes, I was expecting to at least replace the seals while I have it appart. I'll have a close look at it to see if I can understand why Toyota didn't put in double lippers from the start.

One potential problem is that a single lipped seal provides its own lubrication giving the shaft a long life. However the outer lip on a double lipped seal stays completely dry and in a very dusty environment can actually reduce the life of the shaft! Since the box tends to leak oil out rather than dirt in, perhaps a single lipper is the best compromise!
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FollowupID: 5531

Reply By: Member - Graham - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
Pip, I had a similar prob with my 1st 80, it was just on occassion but only when you didn't need it to happen. mine was an ex miner and all it was was a buildup clay-mud&bulldust which restricted the full through of the lever. A good water blast & it never happened again.
just a thought
AnswerID: 10512

Follow Up By: Pip - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
Thought I had done a reasonable job of water-blasting around but only from the side, not up on a ramp. Might be worth taking the rubber boot off from the inside and having a go from the top perhaps. What do you think?

I also see that it is possible to adjust the link rod from the level to the box. Any chance this is worth playing with?
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FollowupID: 5543

Follow Up By: Member - Graham - Sunday, Jan 05, 2003 at 01:00

Sunday, Jan 05, 2003 at 01:00
Yes i did mine on a hoist whith an adapter, there was alot up there, i also hosed myself after. I think taking the boot off would give a clearer view, yes the adjuster is worth looking at . good luck
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FollowupID: 5591

Reply By: Truckster - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
300,000 I would expect to be dishing out some $$ by now !

Probably would be worth a full going over if it gets you another 300,000klms... May seem excessive but if you plan on keepin it, go the whole hog, if you plan on selling it, trade it in, they wont test the 4wd!

Some people cringe at having to pay for some parts sometimes that seem to be expensive (well they usually are arent they!), but if it lasts you another 200,000-400,000klms why argue I think.....

YMMV..
AnswerID: 10528

Reply By: Truckster - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
Would this help you

complete 5 speed conversion,, including flywheel, clutch ,pressure plate, slave cylinder, shifters etc.,, only done 70000km,, was goin to convert my 80 to manual, but im getting to like the auto in the bush,, looking for around $1100,, im in wollongong/sydney its a 94 model 80 series,, full time 4x4,

http://forums.overlander.com.au/messageview.cfm?catid=11&threadid=2797
AnswerID: 10533

Follow Up By: Pip - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
Great offer Truckster, but I like my part-time 4x4 and do not need the box or rest of the bits. (Famous last words!!!) Also Brisbane based which just makes it all a little more difficult. I'll have a closer look at it all and maybe get back to you on this!
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FollowupID: 5553

Follow Up By: Truckster - Saturday, Jan 04, 2003 at 01:00

Saturday, Jan 04, 2003 at 01:00
na Im not selling, this was on the overlander forum, thought it may have gotten you out of the crap...

Take care
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FollowupID: 5564

Reply By: Eric - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
Pip.
End float in the transfer case gears is the cause of gear jumping. New bearings and the correct spacer thicknes will fix it. Dont take any advice in a gregories manual, go to your local library and read the factory book. and good luck. Eric.
AnswerID: 10538

Reply By: Eric - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
Pip.
End float in the transfer case gears is the cause of gear jumping. New bearings and the correct spacer thicknes will fix it. Dont take any advice in a gregories manual, go to your local library and read the factory book. and good luck. Eric.
AnswerID: 10539

Follow Up By: Pip - Friday, Jan 03, 2003 at 01:00

Friday, Jan 03, 2003 at 01:00
Thanks Eric.

This sounds like the info I was looking for! It also fits with my experience on other boxes I had, e.g. TR3's and a Kombie! In each of these cases there was wear in the selector sleeve, so I can see that movement of the gear and shaft due to bearing wear would have the same effect.

Thanks again!

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FollowupID: 5554

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