Fourtrak gearbox

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Hi all,
I've lost fifth gear in my 1992 tdi fourtrak. It was hard to get it in fifth last week but now its just not there Sad Does this mean i need to be looking for another gearbox? Does any one know whether a gearbox off a 1989 2.8 non turbo fourtrak would be compatible? any help appreciated
Sam

hi sam

Been a while mate, what ya done to your gearbox mister??? have you got the other 2.8 na one , it will bolt on, i have a spare one but kinda like to keep it for mine when that eventually packs up ( if it will - 184000 miles and still going), its definitely the gearbox is it??

Full of ideas but no time to do them!!

www.bloodredoffroad.com
www.milneroffroad.com
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youtube: Redfourtrack

It certainly has been a

It certainly has been a while! Suprised you remember me. Well i've only had this fourtrak a few weeks. When i got it it was a bit grindy going into reverse and going between fourth and fifth gear. However i now have no 5th gear at all. I took out a bung on the gearbox the other day thinking it was the oil level bung but apparantly it was the bung that holds the arm for 5th in place. I suspect this is the reason why i have lost 5th. But that doesnt explain why it is crunchy going into gear. Fear the gearbox could be knackered. I still have the old red fourtrack but its had some abuse down the farm so dont know what condition the box is in. So it would bolt straight on to my new one?

How you keeping? Your truck is certainly racking up the miles isnt it mate! Mines done a genuine 43000 so i was hoping it wouldnt need much work. But guess i was wrong. Oh well, thats why i love 4x4s. Drive them, break them, fix them Smile

> When they found him he still had the remote in his hand <

boxy

Oh dear mate you undone the nut for the reverse gear i think it is, anyway im suprised its knackered with those few miles sam, look at all the bolt holes and im pretty sure it will bolt straight on, sorry i was thinking about the trak i saw you in last time, whats the engine no. etc

Full of ideas but no time to do them!!

www.bloodredoffroad.com
www.milneroffroad.com
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youtube: Redfourtrack

Oh dear.

The "plug" you removed was actually the pivot that holds the lever to select 5th gear. Seeing as the arm is no longer on the pivot, but floating around in your box, is why you have no 5th. The crunching is very bad news indeed, I would say that the main/lay shaft has picked up the arm from the bottom of the box, and some teeth have been destroyed. Mine fell off on its own after I had the box off, but lucky for me it fell into a hollow at the bottom of the box and didn't get sucked between the shafts. If I were you I would take the box out, drain the oil, and have a fish around in the bottom to retrieve the arm. Also check what damage has been done to the gears. Not going into 5th very well suggests that the syncro has gone(mine went on 1st/2nd), which would mean a new box. If you need any more details, just ask Smile

I know what you're going through, my heart sank when I tried to change up to 5th after putting the box in and feeling nothing and only getting the increase of revs.....

non turbo gears

Hi Sam,
the non turbo box will fit but the gearing is around 20% lower than the turbo box, If your fitting larger tyres or using mainly offroad or towing this is great, if you travel long distances on A roads and motorways get used to a 60mph journey.
best regards
Dave
Blood Red Offroad Ltd
www.bloodredoffroad.com