Outer Limits 4x4 Board

Just drove down the road and Luxy started making some noise, pulled over and it stopped though it must have been the box front drive shaft so i kept going.
Noise got worse stopped again and noise was still going; shut it down and checked underneath, all appears fine.
Started back up and depessed clutch noise stopped; let clutch out noise starts again. Clutch in and revving no noise so i am pretty sure the motor is fine.
Had to get home so just putted it back but i noticed down hill I put it in fourth gear and the noise stopped; it is the only gear that doesn't make a noise so i think it has to be the actual insides of the gearbox but i just had that rebuilt
Any other ideas

I'm going to assume it's a G52? It'll be the mainshaft gear/input gear/idler gear (one of them ) Probably lost a few teeth - this is the only gear that causes issues in all gears apart from 4th.

-Stu

LuxyBoy wrote:but i just had that rebuilt

call who ever rebuilt it and let them worry bout it.

bogged wrote:

LuxyBoy wrote:but i just had that rebuilt

call who ever rebuilt it and let them worry bout it.

Yeah i'm going to, just wanted to make sure i hadn't missed something else that could be the cause.

If its only when the clutch is released it might be the throw out bearing.

These can make a noise when in contact with the pressure plate fingers and no pressure on the bearing.

The reason it doesnt make a noise in fourth is because in fourth the whole input main shaft is locked up like one big shaft form engine to transfer. The throw out would be making a noise no matter what gear it was in. It is most probably cluster gears ( 1st 2nd 3rd )or bearings on cluster. G52 drop teeth reguarly. Listen to Stu

Thanks guys the gearbox place said the same thing as Stu but won't fix it under warranty. Even though i have driven Luxy for years without a problem until he rebuilt the box
Said their warranty doesn't cover gears only bearings.
If i take it to him; they have a look ($300) and it is a bearing fault then he can TRY to get the bearing company to pay for a full rebuilt including gear sets that he reckons will cost about $5000.
As if the bearing company are going to cop that they are just going to say he installed them wrong

So i am thinking of just getting another box from the wreckers.
The gearbox place reckon a 3 litre Surf box is bigger and stronger and fits in; anyone done this or know of a different box i can put in that is strong and doesn't require huge dollars and stuffing around
Ready to rip his Fing head off at the moment.

He reckons the G/box from a Surf VZN130 with the 3VZ-E motor will fit mine but doesn't know whether the transfer case is the same or will fit and if the bellhousing from Luxy will just bolt.

Anyone know
Have posted on http://www.toyotasurf.asn.au also

Think surfs have a chain driven t-case.

yep chain driven

but the front box is the same
just use a mid 90s v6 box as they are the strong ones

cooter wrote:yep chain driven

but the front box is the same
just use a mid 90s v6 box as they are the strong ones

Don't know what you mean by "the front box"
Had a look at the wreckers and the V6 bellhousing looks different but the g/box & bellhousing from a 5L motor looks like it will mate straight up is it as strong as the V6 box
Can you convert a chain t/case to gear driven (I have duals in the shed ready to go in so I don't really want to change)

surf box is R series (R150?) and use the chain driven transfer case. An adapter is available to attach the gear driven transfer case - you'll also need to stuff around with shifters and possibly swap tcase input shaft. I believe 1st gear is also alot taller which can make them a prick to get off the line with std diff gears (as experienced with my bro's ln106 w/2.4td/33's/std diffs)

Sounds like a good quality rebuild with and excellent warranty 5000 grand for a box is a bit steep, gears are dear but not that much 2 to 3 if you need lots of them...

How long was it after the rebuild, and did they romove and refit the box.

Thanks Stu yeah i think the surf box is R150F did your brother have problems with mating the box to motor
Do you know who does the adapters I had a look on marks but couldn't see one
Apparently there is a wide and skinny version of the R150 so i need to find a skinny and see if my bellhousing will mate up or not. It is just confusing at the wreckers.

Bit more pricey too, from the wreckers the G52 is $660 and the R150F is $1300 Apparently they don't like selling the G52 secondhand because of the failure rate, wish i knew all this before i rebuilt it

LuxyBoy wrote:Thanks guys the gearbox place said the same thing as Stu but won't fix it under warranty. Even though i have driven Luxy for years without a problem until he rebuilt the box
Said their warranty doesn't cover gears only bearings.

what exactly did they rebuild?
DO you have a detailed reciept from them?

Try the local RACQ Legal dept, they will tell you where you stand.

Seems std for gearbox places.

imoput shaft bearing

LuxyBoy wrote:Thanks Stu yeah i think the surf box is R150F did your brother have problems with mating the box to motor
Do you know who does the adapters I had a look on marks but couldn't see one

He brought it bolted to a 2L-T (as per std) and kept the engine on there, but i'd guess a 2L-T bellhousing would bolt up to a 3L (not sure).

The adapter was from mariln crawler, through locktup4x4. He also got an input shaft/gear from either marlin or trailgear (spline counts differ from early to late box's, i think it's the earlier one that is required to suit the marlin adapter)
I can't remember too many specifics but i'll see if i can get him on to give you a hand.

AZZA'S HJ47 wrote:imoput shaft bearing

Seen enough of these box's lose teeth without any sign of bearing failure

-Stu

Much appreciated Stu
There are four different R151F boxes now i just need to figure out what the hell the differences are

dogbreath_48 wrote: but i'd guess a 2L-T bellhousing would bolt up to a 3L (not sure).

Yes, it will fit.

So i just need the box and bell from a 2L-T is the 2L-Te the same
Might get the crossmember too, just in case.

Thanks heaps guys

The late 2-LT bellhousing (from a surf etc) should bolt up to a 3L. I'm not sure about the early 2LT bellhousing from a bundy? Can anybody confirm this?

LuxyBoy wrote:So i just need the box and bell from a 2L-T is the 2L-Te the same

Yes it is.