Outer Limits 4x4 Board

How hard is it to remove the gearbox so I can change the clutch? Are they heavy or is it managable to do it from underneath the car while it is on ramps?

The gearbox and transfer together are like 4-5 foot long, and pretty darn heavy. I would recommend 2-3 people, two can do it but an extra for passing tools is nice.



I modified my 2t trolley jack into a temporary gearbox lift, which definitely helped, as it made it easier to maneuver and less change of it tipping (and crushing your skull/hand/genitals). I made one because purpose built ones are exxy, but if a mate has one - get a hold of it.

Two people and a trolley jack should do it fine.

Mine was made difficult by being non-standard height, and the cheapest trolley jacks don't lift high enough - 2000kg ones give an extra 10-13cm or so in lift which helps.

If you try to unbolt transfer from gearbox, the upper most bolt, facing forwards (visible from engine bay) is bloody hard to get at, even though its like the only one you can easily "see".

Thanks guys ill invest in a trolley jack and get the missus to help

After doing numerous motor/gearbox/transfer/clutch changes, and doing it different ways, I made a rule to remove the lot in one piece, and split it on the ground. Getting that lump out is one thing, getting it back in, and aligned again while grovelling around on the ground, with about 140kg delicately balanced on one floor jack, is not fun.

Yep, your motor weighs 260kg, and the gearbox/transfer case is 140kg, approx. I have just done a transfer case change today, and I reckon it weighs about 30kg alone.

The other thing is the bloody lobsideness of the transmission assembly.

Its much easier to get a loan of/hire/acquire an engine crane, pull the front off the Rocky, and pull the lot out that way.

Thanks Bundy, I think i might get someone to do it. 240kg is to heavy for me

Are we talking a Rocky or Feroza here?

Feroza box and tranny case are easily lifted by one (fit) person when out of the vehicle. Two people should easily manage getting it out and back into the vehicle. Rocky may be a different story.

AJFeroza wrote:Feroza box and tranny case are easily lifted by one (fit) person when out of the vehicle.

Lies! Lol, I lifted one!!

Seriously though, I was talking Feroza, OP on the other hand - unsure. 2 people CAN do it, I said 3 cuz its nice to not have to get under and out from under the car when you forget a tool or need to check something etc.

I got the feroza and it does look lite.

It's awkward but doable - holding the bellhousing and rear extension housing of transfer your arms are pretty outstretched, and your walk reduced to an odd penguin step.

lol I am going to get the gearbox adapter to fit on my trolley jack and hopefully that will take the strain off my missus

OK Chugga, classic mistake on my part, assuming you were talking diesel Rocky, and not petrol, or Feroza. I know Feroza transmissions are a lot lighter.