can't remove gearbox from 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

[Petemcc]

same thing on my surf and had forgotten the two bolts from the starter motor that go onto the bell housing from the engine side

worth a try
Pete

[hulux-happy]

yeh cheers, i wish it was something simple like that, but we checked evey bolt including the starter motor bolts. cheers anyway pete.

[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

[hulux-happy]

yeh tried that aswell but the bering is moving on the shaft so i just dont know what the g/box is stuck on

cheers anyway mate.

[Chopper01]

is it in the hole or out , its not hitting on the fire wall or anything stupid like that

[Jezza]

Sounds like the spigot bearing it seized onto the input shaft the way you describe it. Did you completely unbolt the clutch housing?

[hulux-happy]

yeh mate. its all unbolted and the pressure pack has been unbolted from the flywheel as well. we are stumped and he needs it going witch makes it worse. we can do all the work bar the removal of the g/box. we have tried everything. i just did the clutch on the safari last week and was looking at it to see if there was any clues to the problems with his truck, but nothing at all stuck out as being a problem. everything and i mean everything is disconnected. i suggested pulling it of with my PTO winch, but he wasn't keen as he didn't want the g/box coming out in pieces as it still works fine.
cheers mate i wish the was something simple but unfortunately its a real struggle and seems to be the shaft thats the problem as it comes away from the block all the way round the bell housing by about 5mm but not all sides at the same time and seems to pivot from the center of the clutch....

[Pedro]

yeh mate. its all unbolted and the pressure pack has been unbolted from the flywheel as well. we are stumped and he needs it going witch makes it worse. we can do all the work bar the removal of the g/box. we have tried everything. i just did the clutch on the safari last week and was looking at it to see if there was any clues to the problems with his truck, but nothing at all stuck out as being a problem. everything and i mean everything is disconnected. i suggested pulling it of with my PTO winch, but he wasn't keen as he didn't want the g/box coming out in pieces as it still works fine.
cheers mate i wish the was something simple but unfortunately its a real struggle and seems to be the shaft thats the problem as it comes away from the block all the way round the bell housing by about 5mm but not all sides at the same time and seems to pivot from the center of the clutch....

i would say spigot bearing as well, if the pressure plate is unbolted and and free turning and nothing else is tieing it together and it not hitting the body then spigot bearing is the culpruit, use wedges or chain block to pull back or load the sticknig point, then get a long brass drift and give the side of the input shaft a tap, it may help shock the bearing free, also see if you can get inox or CRC onto the bearing area and let it soak. my guess is the bearing has failed, spun on the shaft and welded itself together

have fun

[4runner]

hi,

my hilux box was stuck in, so me and my mate tied a hand winch round it and to the tow bar and slowly winched it off

hope that helps

[hulux-happy]

we tried that with a 1v tonne chain block but it is stuck hard. its a real bugger. we are going to try a brass drift onto the spline shaft on the g/box in the next few days, so hopefully that dose the trick. he is almost at the point of writing it off. either way i will post more info soon on how we go.

[Pedro]

we tried that with a 1v tonne chain block but it is stuck hard. its a real bugger. we are going to try a brass drift onto the spline shaft on the g/box in the next few days, so hopefully that dose the trick. he is almost at the point of writing it off. either way i will post more info soon on how we go.

if tapping don't work, you could try some heat from a gas torch, if that fails, pull the trigger on the the gas axe and cut the bugger out