TROOPY gearbox problems??

I have a 95 HZJ75 and mine has the hose between the transfer case and gearbox also. It usually means the seal between the gearbox and the transfer case is leaking, and the hose is there to balance the pressure between the two to stop the pressure pushing the oil between the two. If too much oil goes from the gearbox to the transfer case, some will run back into the gearbox.

I dont know what the weak link is, it might be the countershaft is weak or soft or something apperantly they need replacing after a while, but mine suffers from having 5th gear fall out all the time. really annoying.
When driving down a hill at 90km/hr if you genlty lift your foot off the throttle 5th will pop out. Ive just learned to live with it. I figure when the gearbox gets worse then its time to take it out and fix it. While it is still going (and doesnt seem to be getting any worse) i can just leave it.

This is what you want as a cheap fix for the seal issue Site Link

Signman
the answer from longJohn just about sums it mate, and what he said about jumping out of 5th is 100% spot on , about the seal , also 100% spot on, about the hose also 100% spot on except that when I had mine repaired in Mt Isa the buggers didn't put it back so I had to buy a new hose ,

Longjohn as you said you learn to live the 5th gear , as you take your foot of the go pedal the left hand hits the gear lever to keep it in, it was a bugger though when a roo shoots out in from , right foot reacts to fast for the left arm and you find your car is in Nuetral , "angel gear" Mine was like that for months until it stripped the main shaft and then I had no motion at all in any gear, $3500 parted with and away we went and that was about 520,000 Ks

Second and third synchro's seem to be another problem, in our work vehicles anyway. they are traybacks not troopies, but I believe they are the same box. Some have gone as early as 30,000klm and some as late as 80,000klm while some have done them 3 times by the time the vehicle has 100,000klm on it. But they do all seem to do it. The fact that we are on a mine site and the vehicles are fleet vehicles means that Toyota don't cover warranty. Probably a particularly harsh environment, but thats what they are built for? It has been such a concern that the company,(the big Australian), has changed to Nissan. We'll see how they go. No matter what vehicle we have there is going to be a weak link.Our mine site does not have an airbag requiement yet. Not sure what they will do when the last of the 4.2 ltr's run out.

Hi Signman

The problem with the 75 series is this the main shaft looses it hardening between the gearbox and the transfer case, generaly this is caused because of towing in 5th gear under 100kph.

The seal is a common problem in the 75/78/79 series, and the hose does work.

The problem with the 78/79 series, is they changed the main shaft and split it in 2, so the transfer shaft is the 2nd piece.

this was joined by a sleeve that would strip under torque.

!MPG:25

This is Toyota has fixed the problem.

!MPG:24!

This is the transfer shaft.

!MPG:23

Cheers Steve.

Hi Signman.

I will try again.

The problem with the 75 series is this, the hardening of the main shaft is worn off between the gearbox and transfer case.

This is caused mainly because of towing in 5th gear under 100 kph.

The seal problem is common in the 75/78/79 series and the hose does work.

The problem with the 78/79 series is the main shaft is now 2 piece and joined by a sleeve that was to small and kept stripping

Common problem with the early hilux's as well involving the seal. Easy fix and permanant is the hose between the two. Sh#t load cheaper then spliting box/transfer apart and replacing seal and chances are it will happen again. Regards Steve M

Signman
Just found this site , might be of interest to you

www.toyotagearboxes.com/products.html

the hose is not needed in late model toyotas as the transfer and box are seperate and sealed so oil cant go from one to another as in the early models, 5th gear has always been a weak link in toyotas, it is not in the box as such but behind it .i work at a 4x4 specialist workshop and we have rebuilt 3 in the last two weeks from older troopys and a 60 series, always get firm quotes, the parts only cost about 780 bucks, if the mainshaft is ok, the rest they soak up in labour, our tranny,no not that sort, expert can have the box out and rebuilt and back in going in less than 6 hours so be careful you dont get touched.

79 series, by the way 60 series box i mentioned was mine, 504,000 ks. handy having a mate at work, only paid for parts at trade labour was covered by copius amounts of xxxx gold, while i was at it i got excited and pulled the motor and gave the old girl a rebuild as well, liners pistons, all bearings crank was ok, machined the head,{in house}, injectors, gave the cam a lumpier grind , opened the ports a bit, changed fuel to suit and am now running her in, it will outlive me i reckon. just wish they made there boxes as strong as nissan, ouch that hurt to say that, but it is true, cant remember the last nissan box in for rebuild.

same but different, we could sell heaps of transfer hoses, but the boss is an honest man, hard to find in this trade i can tell you, and as katherine is a small place you look after the customers and they keep coming back. i will check with the box man tomorrow and clarify , boxes are not my department, so i will find out and get back.paul.