Outer Limits 4x4 Board

On the way home from work the other night on the highway my 96 t/d lux droped 5th gear it didnt effect any of the other gears and i drove about another 500km to get home in 4th. its done 275 000 k so i guess its time to replace or overhaul it. so my question is. how hard to rebuild them, who has done it? the kit is cheap as. a reco box is expensive around 1000 exchange . or does anyone know of a good second hand box?

will a r150f gearbox from a v6 4runner fit in a 96 lux in replacement of the g52

Is it noisy in 5th gear or is there just nothing at all?

nothing at all, i was doing about 100km/ph and made a bit of a clunk and then nothing, no 5th gear what so eva.

Ok you need to pull the transfer off. Then pull the extension housing of the back of the gearbox.(if your carefull this can be done in the car) There is either a circlip or a nut depending on what model G52 is fitted that holds the gear for 5th on the back of the main shaft. Either the clip or the nut have come off the back of the shaft allowing the gear to fall backwards away from the other gear. Common for the clip to do this but althoughy very uncommon for the nut to do it i have seen it happen. Its usuallly due to towing in top gear lots or lugging in top gear with larger tyres.

Either way if its the nut or clip you need to re-fit them and then place a small weld on them to stop them from falling off again. As long as the box is not noisy in any other gears this will fix the problem. Ive never had one come back after doing this and its a very common fix in the industry.

Thanks for that, i will give it a go

gutlux44 wrote:Thanks for that, i will give it a go

If the clip or the nut have failed it is an easy fix.