Fourtrak gearbox removal

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Im planning to remove the box from my fourtrak this saturday to swap for another box. Anyone tell me how hard it is? Anything to watch out for?
Sam

Box change

Easy, but two differing methods, so its down to personal preference; one is to remove the engine and box as a unit, the other is to remove the box/transfer case.

My preferred method is to remove the gearbox/transfer case as it prevents removing the radiator and front panels. Lift the vehicle onto axle stands or ramps, remove the gearstick from inside the vehicle, lift the gearstick rubber gaitor and underneath is a spring clip, remove and pull the stick out.
Underneath; remove the breather and electrical connections, propshafts, etc.
Unbolt the crossmember and pack it with a jack, lower it slightly to allow access to the bellhousing bolts, you will need extensions and a universal joint to undo them.

DO NOT DROP THE GEARBOX DOWN TOO LOW AS THE TILTING ENGINE WILL DAMAGE WIRING OR OTHER CONNECTIONS AS WELL AS THE FAN PUNCTURING THE RADIATOR.

Place a bottle jack under the rear of the engine to prevent it dropping too low, and check while dropping the unit, that the engine is ok. Remove the box/transfer case on a hydraulic jack by pulling it rearwards to remove, and lower the jack and pull out from under the vehicle. Pack the engine with short boards under the sump and onto the crossmember to prevent it from tipping while you work on the gearbox/transfer case seperation.

Not a lot to it really other than time.

Just one thing to add. Once

Just one thing to add. Once the gearbox is free of the engine, and moved back about 4inches? there is a lifting eye on the gearbox which will now be in line with the hole left in the transmition tunnel by removing the gearstick / transfur lever gatter. Using an engine hoist (if you have one of course) through the pasenger door on this is a lot more stable than using a jack.

Any veiws expresed in this thread by me are purely from my own experience, and (sometimes) falible memory. Hope my comments help, but please don't take them as gospel.

Any veiws expresed in this thread by me are purely from my own experience, and (sometimes) falible memory. Hope my comments help, but please don't take them as gospel.

Table Jacks

Always forget i have a large table jack, this lifts anything.

took the gearbox out of the

took the gearbox out of the donor vehicle. No problems. Just really heavy! Putting it into my truck on friday.

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

Thanks for the your help.

Thanks for the your help. Il have a crack at it on saturday and let you know how i get on!
ATB Sam

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