Outer Limits 4x4 Board

Once you've stripped teeth, the whole gear set usually has to be replaced as well as the bearings, countershaft, etc.

The original "manufacturer" (not seller) of Rockhopper Series 3, Newvale Engineering is in Bessemer St, Blacktown. They maybe able to help you further to advise if it is repairable, but more than likely it won't be.

If you get another gear set, would recommend keeping oil topped up in the T/F case, they work a little better that way.

Do you have a contact number or do they have a website for the guy in Blacktown?

As for the oil, I bought the car Sunday, it broke down Monday, was booked for a service Tesday... Hows luck??? ha ha

Kaz

Podge wrote: The original "manufacturer" (not seller) of Rockhopper Series 3, Newvale Engineering is in Bessemer St, Blacktown. They maybe able to help you further to advise if it is repairable, but more than likely it won't be.

arnt they made in america?

i lack of oil will usually destroy gears. no matter how great they are.

that sux considering you just bought the car

Podge wrote: The original "manufacturer" (not seller) of Rockhopper Series 3, Newvale Engineering is in Bessemer St, Blacktown. They maybe able to help you further to advise if it is repairable, but more than likely it won't be.

arnt they made in america?



No, Rockhopper was never made in America. The US brands might be but not Rockhopper.

KCZ00K wrote:Do you have a contact number or do they have a website for the guy in Blacktown?

Kaz

I gave those details so you could look it up.

Podge wrote:

KCZ00K wrote:Do you have a contact number or do they have a website for the guy in Blacktown?

Kaz

I gave those details so you could look it up.

ah ok, your a great help.....

For all those that don't know or to those who did and didn't say anything, Rockcrawler gears can be fixed for almost nothing of the price it would cost to replace the whole set!
I sent the gear to an engineering company local to me, who specialise in performance gears for racing and rally suburus. I got it back after 3 days, shoved it back in, gave the case a full clean out, checked bearings AND put a litre of oil in it! I took it for a fanging through menai yesterday without a drama!

so what was exactly wrong with ur gears, and how did they repair them?, were there any teeth missing?

All but about 20 teeth were smashed, was lucky it didnt do much damage to the other gears and bearing, took a tooth off my smallest gear but i didn't repair that one.
I tried to add a pic to show everyone but the page kept crashing....

The guy made a templet of the whole gear then sent it to his mate that cuts the teeth in. It took about 3 days and he reckons the gear he made is much stronger material than the gear that broke!

I can imagine the next time I break something in there, it will be the only gear left standing ha ha Gawd I hope not!

Click the link to see the gear!

http://groups.msn.com/Sydney4x4/rockieg ... hotoID=248

Great news. Post up the vendor? there might be a few people on the board that will benefit from them.

stephen wrote:Great news. Post up the vendor? there might be a few people on the board that will benefit from them.

and tell him to keep the template

KCZ00K wrote:For all those that don't know or to those who did and didn't say anything, Rockcrawler gears can be fixed for almost nothing of the price it would cost to replace the whole set!
I sent the gear to an engineering company local to me, who specialise in performance gears for racing and rally suburus. I got it back after 3 days, shoved it back in, gave the case a full clean out, checked bearings AND put a litre of oil in it! I took it for a fanging through menai yesterday without a drama!

How much of that gear did they Re-Make? How much did they Charge you? Did they just cut the large gear off and remake it and weld a new one on or did they re-make the entire gear set?

I'd be keen to have afew more details

I'm keen to learn more as to the Co. that did the work. I have a broken Rockhopper or three in my collection (I think that I have a Series 1 and 3 there). I might be able to get them rejuvenated for future use, maybe even get the bloke that did yours to do the testing on them for OL members to know what the problem is as to why they break.

Was the counter gear the only damaged gear or was the input and output gears damaged also?

Just having a look at the broken gear in the pic on your site, looks like some heat went through that counter gear.

I gave the gear to an engineering company called CNB Engineering, they didn't fix the broken gear he made a brand new one, most engineering companys can do that, but then he sent it to another company to cut the gears, and thats the peoples names I am yet to find out. The guy that made the gear is my fiances friend so we didn't pay full price but i will find out how much a full charge is. I know it isnt alot....
Another place that were keen to do it, and they do everything in their factory, was Par engineering in Minto Campbelltown, they also do high performance gears, but I heard they weren't that good, but I also know a few people who have done quite a bit of business with them and their cars are still going, so make your own decision.
http://www.par-engineering.com/

In my case, only the one gear broke, but chipped 2 teeth on my smallest cog. You are right with the amount of heat, a case running with no oil!!

Im planning another trip soon so that will be the decider as to how well the gear is made, so far it has travelled well on roads and off roads so its looking good.

Sorry I haven't got anymore info for you guys, my fiance took care of the repairs, but as soon as i find out more I will definately post it!!

Kaz

RUFF wrote:How much of that gear did they Re-Make? How much did they Charge you? Did they just cut the large gear off and remake it and weld a new one on or did they re-make the entire gear set?

The large gear is released by a pin, its kinda like 2 peices, so when it was released, its was just a flat cog.

i no why the series 1 were breaking, i checked this out my self, because they r a 2 piece gear, they were not assembeled properly, and had a large about of runout, causing noisy gears and fatigue over time. as for the series 3 im 100% sure it comes down to heat treating, material and finish or profile of teeth.

you should change your oil more often...

mud4b wrote:you should change your oil more often...

Trust me, I am definately more concious of oil levels now