Outer Limits 4x4 Board

Not having fun with this

I have the Zook up on blocks whilst it gets a new clutch, usual problems of doing something like this at home, working under the car, not having a gearbox jack, seized bolts etc

Removed the shifter to allow for dropping the box (in hindsight might not have had to, but I still think it makes it easier to put it back in). I don't recall seeing the locating pin which sits at the rear of the pivot on the shifter at the time. Now when re-assembling everything goes together sweet, however the shifter can swing around. I have tested (whilst still up in the air) that I can change gears. I have removed the shifter again and believe the swinging shifter is due to the fact that there is no locating pin to fit between the hole in the casing and the groove running down the rear of the ball on the shifter.

Could I have dropped the pin into the box? If so what damage? Will the gears just crush the pin such that it will come out when I drain the oil?

Not having seen the pin, is it metal or plastic? I assume I can obtain a new one from Suzuki?

Someone who is more familiar with this please help.

it's only little maybe you could buy some cheap engine oil and try an flush it out,and then put gear oil back in.i use engine oil to flush because you can normally get it cheaper

isn't there a pin on both sides

it is metal/ you can get a new one from zook. if you can shake box a bit to see if anything rattles. usually it would only fall on the shifter forks under the stick.

was it loose before. also there is a bushing in there as well. a cup shaped thing.

cheers

ur drain plug has a magnet on it if ur lucky it will be there and not jamed somewhere.

Update

I removed the top plate from the gearbox, hoping to see it just sitting there on top of the forks. didn't find it but was able to find that as the locator screws in from the rear of the plate, that mine had sheered off somehow. Thinking laterally i went round to MadZook's place and took the shifter off of the Drover (that thing will never get back on the road, but gee it has been good for parts) i removed the locator pin and was able to confirm that about 5mm of unthreaded pin wich protrudes from the housing into the rear of the shifter was missing from mine.

I am now about to drain the gearbox, whilst admiring once again the thinking of whoever decided to make sump plugs with magnets in them. With a bit of luck, it will have passed between the gears and will drop out. If not, drive until it dies then back to MadZook's to remove a gearbox.

This happened to me once while replacing the pin - as mine had snapped as well. The little peice had fallen down inside and was sitting just under the locator/selector bits. After I had removed the top plate I was able to fish around with one of those flexible magnetic tipped things (couple of bucks from super cheap auto!) and pull it out.

All good now. I dropped the oil from the gearbox and found the little unthreaded piece in the drain tray, it matches perfectly with the sheered off thread so looks like no other pieces. Reassembled with the replacement pin, test drive went fine. The shifter is actually more precise than it used to be.