G52 Disassembly

[Sam.BMX]

G'day guys, my 93 hilux broke its G52 trying to clutch start in reverse. The shifter has jammed in reverse and will not move at all on the gearbox. What I need to know is, is it possible to pull down in the shed and see whats wrong, or take it to a gearbox shop. If we can disassemble it at home, does anyone here know of any websites or books to guide me through it?

I have tried searching here and the internet but have had no luck.
Cheers, Sam.

[old lux]

Mate 4 bolt in the top cover where the gear stick is. Make sure the shorter is in the right spot and hasn't popped out and locked up. I know cruiser boxs are a common failure locking in 5th or reverse haven't heard of the lux box doing it tho.

[Sam.BMX]

Thanks old lux, the old man and I managed to get the transfer case off it and worked out it has to be split in the middle. We took the shifter housing out straight away because the shifter was jammed in reverse and we couldnt get the box out of the car with it in. Now we have managed to get the adaptor housing loose, but its fouling on something inside the box. We aren't sure if its because its still jammed in reverse or if we have missed something to take off. We took off the detent and the bolt on the shifter shaft as the manual said but are unsure where to go from here.

Have we missed something to remove before the adaptor housing can come off?
Or is it because the box is jammed in reverse?

We also noticed there is a crack in the casing on the LHS just above the Torx bolt that says "do not remove" on it.

So any help into what next to do?

Thanks Guys

[want33s]

Clutch starting in reverse (the shortest ratio in the box) isn't a good idea. It puts way too much stress on the gearsets.
I would say you have bent the reverse idler shaft among other bits.
Don't bother trying to fix it just source a replacement.

[Sam.BMX]

Hey want33s, I forgot to mention that a syncro keyway thing did fall out of the box when we dropped the oil. Now reverse wouldn't have these would it?
We'd still like to dismantle it, just to see whats happend.

Cheers

[Sam.BMX]

Hey guys, I thought I'd better update this.

Whats happend is it looks like when we tried to roll start it in reverse that its broken the 1st/2nd syncroniser, which is weird cause I managed to drive it around the block before the box went bang. Then, when I went to reverse it up my driveway the syncroniser came round and jammed reverse, this has also snapped the selector to 1st/2nd. From what we could see after we got it apart, none of the gears are damaged, reverse is a little worn from it, its only broken the syncro and the selector. So we're getting it fixed, throwing bearings through it, all the usual stuff and we got the housing welded up as it had a little crack from where the syncro jammed reverse. I'll post some pics too.

Cheers guys, Sam

[Sam.BMX]

You can see the broken selector at the bottom of the pic and thats what the syncro looks like