Transfer Box Jigsaw Puzzle

Submitted by Einstien on

Forum: 

Hi - been given a Daihatsu that has something wrong with reverse gear - The interesting thing is that the guy that gave it to me also gave me a washer that apparently came out of the transfer box somewhere.... now I've taken the casing off the transfer box but cant see where this washer would go, or why it would effect revese gear....

Here is a link to a pic of inside the box:

Here is the missing washer:

Hope someone can give me a hand.... The symptoms are - it will go into reverse easily - you drive back for a bit, then there is a horrible noise and you stop moving, on dipping the clutch the noise stops, you can then re-engage revese and go back some more.... weird if you ask me????

All this due to a dodge repair by my neighbour!!

Thanks guys

Dave

jigsaw

Submitted by mark4trackemids on

problem sounds like some stripped teeth on the reverse gear to me.
from the picture it looks like the washer should be between the two cogs on the middle spline as it looks like there is one on the first spline with a bit sticking out could that bit fit the two cutouts on the spare bit. but only an educated guess might be worth showing pics to a local mechanic if someone on here doesnt know (which would surprize me loads of clever sods on here) all the best mark....

Nothing beats being up to y

Submitted by Dave H on

Nothing beats being up to yer ar*e in cogs, circlips, bearings and the like not knowing exactly what you are looking for, eh?

Personally, I would start by removing the t/fer box and running it in reverse and seeing if it bangs away then, just to eliminate it - it could be a stripped reverse gear as mentioned above. Then get hold of a manual and look for an exploded diagram of the transfer unit. If there is a part no., on the washer then that will make the job even easier.

Dave with a Sporty

Dave with a Sporty

Ummmm not certain but....

Submitted by Einstien on

I'm almost convinced its not teeth on the reverse gear - you can do a fair few meters before it makes the noise.... far too many for it to be part way round the gear???

And sorry no prize yet - the washer can't go between the gears on the middle shaft - the two gears are joined (i.e. one casting)

I'm getting more and more confused.....

Einstien That thrust washer

Submitted by bundyrumandcoke on

Einstien
That thrust washer comes from your input shaft. Which, in your pic, is the upper most shaft. That is the one which you removed the nut from. I hope you also removed a spacer, about 1 inch wide from behind the nut as well. First check, does the washer fit over the splined part of the shaft, If so, then there are two possible places that washer came from. The first is between the first bearing you can see, and the gear. The second place is behind the last gear, and the casing.
Now, if you did not remove that inch wide spacer, then your reverse gear problem could be here too, As there would be nothing to stop the gear coming backward against the bearing on the rear of the lay (middle) shaft, and jamming up the whole thing. By the way, that inch wide spacer is there, because it replaces the drive gear when a PTO unit is fitted.

Hopefully this,
http://groups.msn.com/AussieDaihatsuRocky/davidsrocky.msnw?action=ShowPhoto&PhotoID=214

and this

http://groups.msn.com/AussieDaihatsuRocky/davidsrocky.msnw?action=ShowPhoto&PhotoID=215

may be of use to you. You are looking at component number 31 (2 of) which is the culprit.

Good luck.

David

Growing old is compulsary, growing up isnt, and
MUD MAKES EXCELLENT TOOTHPASTE

Please visit http://groups.msn.com/AussieDaihatsuRocky/_whatsnew.msnw

Growing old is compulsary, growing up isnt.
MUD MAKES EXCELLENT TOOTHPASTE.
I use billion dollar satellites, to find Tupperware.
Please visit http://groups.msn.com/AussieDaihatsuRocky/_whatsnew.msnw
All views and advice offered are my own, from my ow