Outer Limits 4x4 Board

As some of you know, we now have a Nissan. The Feroza is being sold. But before I can sell it for the money I want for it, a few things need to be fixed up. The big one's are the rear main seal and second gear syncro.

Obviously, the gearbox needs to be dropped to do the rear main. To make as much profit as possible from the sale, I will do this myself (I've done it before). My brother is a mechanic, and usually helps me with this stuff, but he moved to NZ to start his family, so I am sort of on my own.

So a call for assistance is being made, mainly to put the box back in. I am on the Gold Coast, so if anyone can help in the next few weeks it would be greatly appreciated.

I heard feroza boxes are light as, is this true?

marco (my brother in law with the roza) needs to change his clutch, apparantly he has been told its an 8 hour job on a feroza, I call that BS.. how long did it take you?

sorry for the hijack

Are they a cast steel housing or ally? the hilux ones are all aluminium and I can push it up without assistance, but the one under the F20 is all steel and I used a couple of well placed bottle jacks. Bolting the crossmember to the box will make it infinitely easier to handle.

They are very light. The last time, we put the box and xcase on my brothers chest and he lifted up in to place. He's not a big bloke, so this would give a good idea of how light they are. Assistance was given with a rope tied to the rear and lifted through the shifter hole.

Doing the clutch is easy enough. I would say at home with a couple of bottle jacks and a floor jack, and 2-3 people, could be done in 4 hours. But if you dont know what your doing, give yourself the day. At a shop, with the right equipment, could be done in 3 hours.

The gearbox & transfer case are alloy and are light as.... and whoever said that it was an 8 hour job to change the clutch must have rocks in their head.... 3 hours tops!!!

I must be a dumb ass as well as a weakling. I have done this swap four time now...back an forth from part time to full time back to part time when something breaks. Each time it has taken me at least 6-8 hours by myself with no air tools. The transfer case alone weighs about 70lbs. The last three times I used a tranny jack which made it easier to line up the pilot shaft to the pilot bearing. The tranny and xfer case together are ungainly and heavy. The first three times were done out on the street in front of my apartment. The last time my Dad let me use his garage as it was winter.

Without a lift there isn't much room to work.

Pics of Dumbass and the other of me Dad trying to give me a hand...he could only take so much swearing coming from under the truck

Heath,

Plenty of comments but nobody has come forth to offer assistance.

Seems like the gearbox will weigh somewhere between 10kg and 500 kg.
Probably depends if it is full of oil or not.

So I guess I had better make an offer to help a fellow Daihatsu owner.
(once a Daihatsu owner, always a Daihatsu owner)
You never know I might learn something.

I'll PM you with my contact details.

Stu
Brisbane

Heath,

I didn't mean to sound depressing and I would give you a hand if I didn't live so far away. I always took the shift linkage apart and put it back together from under the truck. There is one bolt that is a @$% to get in and out as you can only turn it about 1/8 of a turn with a wrench. You are aparently a lot smarter by removing the shift boot and getting it from the top. I could never recruit any assistance for the job. Good luck mate and sorry that I can't help.

Heath,
Your fortunate. 4WD Monthly recently did a review on Ferozas, and one pic showed a guy holding an alloy gearbox and transfer case combination in the air. I think they are reasonably light. The Rockys are very different. Gearbox and Transfer case are both cast iron. Either is difficult for one person to shift, bolted together, they are damn near impossible. I now make it a habit to remove motor/gearbox/transfer case as one from the car if any work is needed in this area. Last time we did it under the car, it took 3 guys to get the darn thing back into place.

if it makes u feel better heath.. i'd help in a heartbeat. but sadly i live in another country so no luck there bud. sorry dude... come over here and we'll work somethin out. lol

Thanks for all the comments etc guys. As I said, I have the box out in the backyard before, so I know how to do it, and how light the buggers are.

Still tossing up how I will do these things, so I will let everyone know ASAP.

Cheers again