lid on and selector balls/springs in place

getting there, slowly

transfer box now all cleaned up and seals being replaced

replacing the thrust washers on the intermediate gear as old ones (top right) were worn - bearings, shaft and gear ok.

using engine hoist and girder trolley to bring both boxes together (may as well use the tools...)

made alignment easy

bolted up

The day has come, a free home-alone weekend, so log-rover into the garage for its box-swap. door off, oils draining, and work has started before 8am.

hydraulic pump will have to be detached from the gearbox and moved out of the way

this is what came out with the gearbox oil so far - a few bits of broken teeth perhaps?, so brass swarf stuff?, and plenty of metallic paste collected in the drain plug recess

floors out and the gearbox tunnel removed

from below (advantage of having a pit)

and its down and out

old and new

clutch release being swapped over

early on day two and the box finally aligns and is bolted to the engine (was very tricky doing by myself with just a trolley jack...)

transfer box from below, hydraulic pump and gear fitted, handbrake fitted, all ready for the cover to be sealed on at the end of day two - ready for oil in the morning..

having tested the box was working fine, floors and seats bases back in and levers fitted

seats refitted

finished job - everything fitted and working

and back ready for action

there has been two problems since the gearbox rebuild - a rattly transfer box when in neutral and 2000 rpm (ie. when driving the hydraulic pump) and reverse kept jumping out - so removed the transfer box first

took main shaft out and bearings out

replaced bearings, thrust washer and circlip

all re-assembled with the front housing box and the intermediate gear just for endfloat checking

next decided to remove the main box rather than attempt to remove reverse gear in situ

have to remove a fair few bits

transfer box and bellhousing out of the way

reverse gear removed (left) compared with new genuine on the right...