Outer Limits 4x4 Board

Hi,

A mate has just called me during a road trip to bourke from sydney and said his 5th gear has started popping in his 90's 4 runner. He's had it a week

It has a rebuilt gearbox fitted 50,000km ago.

I've read that they can lose a circlip and physically lose 5th gear - creating like a neutral, but this is popping out of gear, - it happened the first time when he got off the gas suddenly when he saw a roo on the side of the road - the sudden change of load from gas to engine braking made it pop out.

Its done it 3 times since, both during change in load.

From past experience I would say the gears are worn.

The rest of the box is very nice and shoudn't need a full rebuild, so is it simply worn gear teeth which causes 5th to pop out?

If so can we just put in a new 5th gear?

Can it be done in the vehicle? (i know it can with some vehicles but not all)

Is replacing it a home mechanic style job?

We do everything to cars but I've never opened up a gear box before.

Cheers
Thehanko

might be worth checking engine /gearbox mounts are not broken, and making sure the gearstick has enough room where it passes through the tunnel.

Its common for the factory shift lever ball seat to wear, had the same thing happen to me with it popping out

http://www.marlincrawler.com/transmissi ... ball-seats" onclick="window.open(this.href);return false;

Clanky wrote:might be worth checking engine /gearbox mounts are not broken, and making sure the gearstick has enough room where it passes through the tunnel.

great tip - will check this. clearance is ok as i checked that but will check the mounts.

Landcruiser power wrote:Its common for the factory shift lever ball seat to wear, had the same thing happen to me with it popping out

http://www.marlincrawler.com/transmissi ... ball-seats" onclick="window.open(this.href);return false;

Interesting... Did this on a sierra before and didnt know the hiluxs suffered the same fault - I will definitely check this out too as gearboxes are not cheap!

Yeah the ten dollars was alot cheaper then a rebuild, and if I had taken their advice, I still would of had the same problem after a full rebuild, gota love Google

Landcruiser power wrote:Yeah the ten dollars was alot cheaper then a rebuild, and if I had taken their advice, I still would of had the same problem after a full rebuild, gota love Google

no go im afraid - mounts look good, ball seat all good.

Looks like im back to thinking worn gear.

does anyone know if just 5th can be replaced? and if its a box in or box out job?

cheers

I'm affraid with 5th poping out, its a gearbox out and transfer off job. Sounds like you will need to replace the 5th hub set and counter 5th gear itself (they wear on the slines on the inner and outer hub that locks it into 5th)
Its a very common problem and not exactly cheap. around the $600 - $800 job.