Gearbox and Clutch

[tkn]

General answers to some of your questions -

1. Life of a gearbox (general duties including [not constant] towing) is about 250000Km - some models last longer, some less so.

2. Two lots of transmission oil to change - first lot in the gearbox itself and second lot in the transfer case.
The oil in the transfer case may be thicker (i.e. heavier) than the gearbox oil.
If your gear changes are difficult when the vehicle is cold, you might look at a lighter oil - e.g. grade 80 instead of 90

[John The Pilot]

Hi Whitestickle,

In answer to your questions of how to remove the gearbox this is how I did it on my own. First I used 4 car ramps that got the Ute about two foot clearance under the vehicle. Next remove all the inetrior parts Eg. seats, floor mats and gear stick boots. Now beg, borrow or hire a transmission jack this made the job so much easier. Remove the drive shafts, exhaust, hand brake cable and all the wiring. Place the transmission jack under the main section of the gearbox and using the chains firmly tie it down. Take the weight and undo the rear gearbox mount and remove, slowly lower so that the sump is nearly on the tie rod, place a jack and piece of ftat wood under the sump and take the weight. Remove all the bolts and now carefully move the box back away form the motor about 3 inches, slowly lower and move back. The gearbox should lean down at the rear and give you enough clearance to turn the gearbox 45 degrees with the rear section going under the chassis rail. Continue to lower and move the box up the gearbox well away from the motor. Change the clutch assembly and do the revervse to put the box back in. Also I found using the wind up jack on the back of the box helped raise the box in line with the motor, place it on the tramission jack itself so it can be raised at the same time.
I hope this helps

John The Pilot.