Outer Limits 4x4 Board

Bad luck story...Changed the gearbox oil in my low km MY05 TD42 the other day and when I did the oil filler plug up, the gearbox housing cracked off the side of the filler plug boss. To say I was and am pissed off about it is an understatement and before anybody flames me for over tightening the filler plug, I didn’t…the f#arken housing just cracked at light to moderate tension!.

The crack is only short and fine, maybe 10 to 15mm long, runs across the end and along the side of the boss and is now seeping oil.

Repair options as I see them:
1. Try V’ing out and welding the cast housing insitu, which is likely to cause the weld area to go hard and also risk buggering the internal thread which may not be able to be repaired if HAZ goes hard.
2. Perhaps try brazing the crack??
3. Replace the gearbox housing with another one, maybe from an ealier GQ.
4. Replace the entire gearbox with a newish one ($$$).

If I change gearboxes to one say from an older GQ, I gain the option to run PTO if I ever want too, but probably also pick up stuffed syncros, bearings, etc.

So, the real question is: Can I transplant my complete MY05 GU gearbox internals into an older GQ gearbox housing? Does anyone know if the newer GU gearbox internals will "just fit" into an older GQ gearbox housing?

Any other repair suggestions welcomed.

patrolswb wrote:Bad luck story...Changed the gearbox oil in my low km MY05 TD42 the other day and when I did the oil filler plug up, the gearbox housing cracked off the side of the filler plug boss. To say I was and am pissed off about it is an understatement and before anybody flames me for over tightening the filler plug, I didn’t…the f#arken housing just cracked at light to moderate tension!.

The crack is only short and fine, maybe 10 to 15mm long, runs across the end and along the side of the boss and is now seeping oil.

Repair options as I see them:
1. Try V’ing out and welding the cast housing insitu, which is likely to cause the weld area to go hard and also risk buggering the internal thread which may not be able to be repaired if HAZ goes hard.
2. Perhaps try brazing the crack??
3. Replace the gearbox housing with another one, maybe from an ealier GQ.
4. Replace the entire gearbox with a newish one ($$$).

If I change gearboxes to one say from an older GQ, I gain the option to run PTO if I ever want too, but probably also pick up stuffed syncros, bearings, etc.

So, the real question is: Can I transplant my complete MY05 GU gearbox internals into an older GQ gearbox housing? Does anyone know if the newer GU gearbox internals will "just fit" into an older GQ gearbox housing?

Any other repair suggestions welcomed.

From my understanding, the internals are the same. The only difference inside, may be the ratios, as there are two boxes, with the only difference being the ratios of first gear and fifth. On the outside the stick is located more forward in the gu box,

Thanks Lawrence. Had just read in a couple of other posts about the shifter movement. Hoping this may just be just to do with the top shifter housing and not the main housing itself, but thitselfat really is a long shot.

They shifter part cant be swapped between the to. From memory the GU shifter is further forwards. Everything else is pretty much the same between the two.

You could try an epoxy resin if the crack is not structural. Then you dont need to do any major work on your car for the time being.
This is the best stuff I have seen / used, but is rather exxy, though chances are you wouldnt ever need to take the box out if you used this. You will be surprised how heavy a container of this is too.
http://www.belzona.com/products/purpose ... epair.aspx" onclick="window.open(this.href);return false;

http://www.belzona.com/products/1000/1111.aspx" onclick="window.open(this.href);return false;

There are others such as quick metal, epoxy metal etc if the Belzona is not available in your area.