stupidity, gearbox/transfer case help please!

[Mongoose]

So I thought I'd give my whiney gearbox in the 60 series a dose of Moreys and some fresh oil to try and shut it up a bit.
Bit of an awkward fit to get the Moreys bottle into the filler hole so I extended it with a short piece of fuel pipe, thinking to myself, best be careful not to drop that into the gearbox.....

So yeah, I dropped it into the gearbox. Took the drain bung back out but I can't feel the pipe in there or through the filler hole.
Once you've stopped laughing some advice, bright ideas would be awesome. At this stage the only way out I can see is to drop off the transfer case which I've not done before and the only advice in the Gregory's manual is for separating the two once you've removed gearbox and transfer from the truck.

So umm, help!!

[Sadam_Husain]

did you drop the tube into the gearbox or transfer box?

[kbushnz]

If its in the Transfer case, Can you remove the PTO cover and fish it out?
Or if its in the Gearbox, is there room to take off the top cover?

Calvin

[Mongoose]

yeah it's in the gearbox, would there be room to get the top cover off and actually be able to get in there? I would think the carpet would need to come out and go in from inside the truck, even then I would think it has managed to drop down into the bottom of the box.

F&ck I feel so bloody stupid. It's tempting to just drop out the transmission and transfer as the syncro is tired on 1st and 2nd and there is a pretty bad whine in 4th and 5th. Could do with having the truck in 2 weeks time though as we're going away for the long weekend and I've never attempted anything like a gearbox recon before. Thanks for the ideas guys.

[Sadam_Husain]

wont acheive anything taking the transfer case off if its in the gearbox then, be worth spending some time trying to fish it out before you go to the trouble of taking the cover of the top of the gearbox to get it.... thats asuming you can take the top of the gearbox off with it still in place in the vehicle?

[H2OLOVA]

Top cover for gearbox is easy to remove. There is a big plate that surrounds the gearstick has about 8 10mm bolts holding it in place, once thats off you can access the top cover bolts from inside the truck.

[Mongoose]

Thanks Sadam, I've had a bloody good fish round with a couple of long screwdrivers with no luck so far.

Thanks Jase, maybe that's the best way to go, see if I can see it and fish it out. Thanks for the advice guys!

Cheers.

[Mongoose]

Jason, does the gear lever need to come out to be able to take the top cover off? Just undoing the bolts now...

[sig]

doesn,t have to but make sure the gearbox is in neutral before you take the cover off .Makes it easier to line it up and put it back on after

[Mongoose]

I ended up taking the lever off as I wanted to get on with it, I'm actually not sure whether it was in gear or not when it came off.
The top cover was a prick to get up through the hole in the transmission tunnel. There's a small short shaft with a rubber boot over it sticking out of the back of the cover which didn't seem to be connected to anything and it makes the cover too long to come up through the hole.

Managed to twist it enough to pull it up but it's going to be a prick to get back in.

Good news though, managed to get a couple of long screwdrivers down to the bit of rubber tube and fish it out!!

Thanks so much for the advice guys, hopefully I can get the oil into it and get the cover back on tomorrow

[rokhound]

Put the oil in through the top while you have the cover off

[Mongoose]

Yeah thanks Rok, if nothing else good has come out of the stupidity at least I can get the Moreys and oil in nice and easy
Bit nervous about getting the "cover" back on, didn't realise all the gear selector forks etc. come off with it. Plus the warning to make sure it's in neutral, which I have no idea if it is or not. It definitely was a shitter to get out through the hole in the transmission tunnel, I can see getting it back in and trying to keep the gasket in place is not going to be fun, plus making sure the selector forks are back in place properly.

Ah well, fun day tomorrow, glad I have the day off.

[Mongoose]

by the way, anything I can check while the cover is off to establish condition of the gearbox? obvious bearings to check, what the teeth on the gears should/shouldn't look like?

[Sadam_Husain]

by the way, anything I can check while the cover is off to establish condition of the gearbox? obvious bearings to check, what the teeth on the gears should/shouldn't look like?

just dont knock all the dirt and shit in there while its off

[H2OLOVA]

Pretty sure the little lever that gave you shit is the selector for 5th gear.

[Mongoose]

Sadam, I gave it a bit of a cleanup, few little bits of dust n stuff got in there but I can wipe that off. Have covered it up for tonight.

Jase from looking at the manual I'd say you're right, can't really see from the manual how it's meant to work as it really didn't look like it was connected to anything. Will have a better look tomorrow. Really glad I started this job...

[H2OLOVA]

Really glad I started this job...

all said without the slightest bit of sarcasm Hey the fun really starts when you have to put it back together. That Moreys shit better be worth the hassle aye

[Mongoose]

Really glad I started this job...

all said without the slightest bit of sarcasm Hey the fun really starts when you have to put it back together. That Moreys shit better be worth the hassle aye

Yeah mate, no sarcasm it's all a great learning experience. If it still whines after this, I'm sellin the fuckin thing and getting me another Lada That's presuming of course that I actually get it back together, maybe I should stick to computers

[Mongoose]

Yep so this is, as expected, a total bastard to get back in. It'd be much easier if the little 5th gear selector shaft wasn't there, maybe I'll just pull it out and live with a 4 speed box

It would have been a nice idea to make the hole in the transmission tunnel actually big enough to allow you to easily remove the top of the transmission and put it back, thanks heaps Mr Toyota.
tw@t.

[Mongoose]

well after buggering around for a couple of hours I just bent part of the transmission tunnel out of the way so I could just drop the cover straight down so the selector forks and the reverse lever went into the correct place easily. Stuck the lever back on and it feels like it's engaging all the gears so phew

Now to just change the oil on the transfer case, without using any short pieces of pipe Then start it up and make sure it does still have as many gears as it used to.

Thanks heaps for the advice, was a hassle but alot less hassle than taking the damn gearbox out.

[albundy]

To make things easier in future get and old sump and make a cover for it and make a stand ofr it as well.. Using the oil return pump in reverse (using a drill) and a leght of hose you can make yourself an excellent oil change pump thingy for doing oil changes. Never falls off into the box/diff/engine.
Al

[Mongoose]

awesome idea Al, I happen to have a spare sump sitting in the garage too

Took the big old lump for a drive and the gearchange is heaps smoother and the bearing noise at idle which went away if you dipped the clutch has gone altogether. Still a noticeable whine in 4th and 5th but quieter than it was. Changed the transfer case oil too, glad I did as it didn't look very pretty. Not sure the PO ever did any servicing at all eh.
Best of all I still have 5 gears and an actual reverse so I guess I got the selectors and cover back in place properly. Awesome way to spend a sunny day off. No wait...