gearbox stuck on azza's bighorn

[hulux-happy]

hi guys,
me and azza have been trying to remove the gearbox on his bighorn. i seems to be hung up on the spline in the center of the clutch plate. we have checked and checked again all of the bell housing bolts are out and the mounts are all of. we had a trolley jack under the g/box, but alas nothing. the gear box will come away from the block all the way around the bell housing by about 5 mm but not all at the same time. we tried a pulley block on it to try pulling it back, but that didn't work either. we have lifted it and dropped it down but the motor comes with it. we have tried leavers and pry bars, but again no luck.

the pressure pack has been unbolted from the flywheel threw the clutch fork hole and we even tried prying the pressure pack of the flywheel but still no luck, so we are out of solutions now.

has anyone had this problem, even on other trucks? we just don't know what to do so any help would be great.

cheers, steve

[mudgripz]

go to clubisuzu.com and ask question there - someone will know.

[Chopper01]

I had something similar happen to me on my old 5m and it truned out to be the thrust bearing was rusted onto the main shaft and it took farken ages to get it off with big bars leavering it out

[Steve_t647]

I agree with chopper if you can get 5mm clearance all the way around then there is something siezed or has bound up and the bearing is the most likley. If you are replacing the clutch etc then get in there with lots of CRC (not good for the clutch tho if you are not replacing it) you could be lucky.

You may be able to undo the bellhousing from the gearbox (if you can separate it on a Isusu) and get CRC in the back that way the only other option is to get some heat in there and then let cool or try crack whatever is stuck (cold chisel) if you can see it, but brute force is probibly your only option.

I have seen someone smash a removable bellhousing off to get a gearbox out, rough bugger but it worked it was a bearing issue.

Good Luck