Problems with Patrol five speed gearbox

[mike]

I have had two problems with my Nissan five speed gearbox which came from a TD 42 Patrol with about 65000 km on the clock. The first problem was the the inablility to engage fifth gear which occurred at about 80000 km and the second was trouble with the reverse idler gear which occurred a couple of thousand kilometres later.

The second problem occurred when I was travelling slowly down a steep incline in the Transkei. I heard a rattling noise which we found later was the reverse idler gear bouncing around in the box. We found that the idler gear shaft had moved forward out of position and released the idler gear. The shaft is located with a small plate that engages a slot in the shaft. The bolt that holds the plate in position had come loose and presumably was also circulating in the back part of the gearbox. Luckily I heard the noise and stopped immediately.

Consulting the workshop manual

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With the help of some friends we removed the gearbox.

The gearbox removed from the vehicle

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We took off the top access plate and the side PTO plate and could then get at the shaft and gear, but not the locating plate and bolt which was in the back part of the box. Unfortunately we could not get the idler gear out of the box without removing the main shaft with all the gears, which we were reluctant to try.

Trying to get the idler gear out

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Trying to remove the bell housing

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We managed to get the idler gear and shaft into their correct position but with the shaft back to front with the end protruding forward from the bearing and with the slot exposed. We then carefully drilled a 4 mm hole into the side of the gearbox opposite the slot in the shaft. This was the only way we could think of to ensure that the shaft could not slide forward again.

Drilling into the side of the gearbox

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We cleaned out the hole and epoxied the drill into position with the end of the drill in the slot in the shaft.

The gearbox reassembled and ready to be washed out

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After washing out the box with some diesel and replacing the oil we got the gearbox back into the vehicle.

Getting the gearbox back into the vehicle before it gets dark

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I drove about 1500 km home with no problem.

I had the gearbox overhauled but was unable to get a satisfactory explanation neither why the idler shaft had come loose nor why I had been unable to engage fifth gear.

Has anyone else had similar problems?

[Tjaart]

BLixem

Job well done!! That gearbox is moer heavy to handle. I replaced the crankshaft seal once, and it was a hell of a job. .

Unfortunately, , I've got no idea how the parts came undone... .

Dalk die tokkollosie...

[KOOS BEST]

Hey Mike, nice FWD Control, I had a 68 ser 2B , sold it this year , after 10 yrs trouble free, was an Ambulance body and had great fun, was a fantastic beach holiday vehicle when we were still allowed on the beaches, mine was stock std with 2.25P engine.
It is now busy getting converted into an overlander with a v8 in the FS .

About the box, hell you guys tackled a major big job there., well done!!!!!

[Stefan]

Hi Mike,

Where & When did this happen? The chap with the motocross gear was at Varsity with me.

[mike]

Hi Stefan

This happened near Mpame on the Wild Coast over Easter 2001. The guy in the motocross gear is Sean, my eldest son. The guy in the white tee shirt consulting the workshop manual with Sean in the first picture is Dave, another son, and the guy with the light green tee shirt is Cuan also my son and Dave's twin brother.