HJ60 GEARBOX

Hi morto, In regards to your HJ60 gearbox you didn't say whether it is a four speed or a five speed. My experience is for a 5 speed box. Points to note are
1. five speed boxes tend to be a bit notchy to get from 2nd to 3rd and vise versa when the oils are cold. So it is important to change the oils in the gearbox and transfer case at 30,000 ks. or sooner if used for heavy work. Use a good oil, some oils don't do much to assist in gear changes. I use Castrol Multitrax transmission oils. Do a search through the Casrtol website for info on oils for HJ60s.
2. Do not tow in 5th gear, unless there is practically no load through the drive line. I say if I'm using more than a 3rd of throttle drop back to 4th. This also applies when not towing and a long or steep climb is approaching change back before you hit the hill.
3. Monitor the oil levels between the gearbox and the transfer case. The oil seal between them tends to leak and can leave the level in the gearbox lower than required. This needs only to be checked at 10000 ks. Some people fit a flexible hose between the 2 oil level plugs to maintain levels.
Good Luck, Ian R.

Mates HJ60 2H has done it for a few years now, there was a slight gring in second and third gears, he took it to a couple of transmission places and they all said it is the gear that has been disengaged spinning after it has been unloaded. As these boxes wear it allows an ever so slight sideways play in the gear and as a result it knocks from side to side as it spins down. Was told it is normal and not to worry aout it. He has never been fully happy with it but it has not got any worse since it started.

It did the Cape last year and has 585,000km on original donk and gearbox although the rear crown wheel had worn and was replaced at about 500,000kms. My personal opinion is that whilst they may go forever they will enevitably develope a few characteristics (Ie, personalities) as the years tick by.

Give it a dose of Nulon transmission stuff. I gave the Troopy a dose a few months ago- and it did make a dramatic difference.
It's taken the 'graunchy' 2nd to 3rd change much smoother, and overall gearshifting better especially when cold...

Rob,
If you're interested I have a 1988 HJ61 SAHARA with 12HT turbo diesel Im going to sell in a couple of months.Motor still strong as ever and gearbox was rebuilt in 2002.Ive had vehicle for 14 yrs.I now have a ute for work/trips.Vehicle body not that great(rust). clancy29@aapt.net.au.(Townsville)
Cheers,Mark

Hi Rob!
I would not worry about it much. I use to have 60 for almost 10 years from 180K to 350K and it was always like that regarding 3-rd gear engaging. Put good oil in gearbox and change it periodically. With time you (or your son) will develop technique to shift to 3-rd with minimum noise. And BTW now I have 80 and it has similar (although noticeably less) symptoms. I recon it some kind of design issue.
Cheers.