Outer Limits 4x4 Board

So I was on my way reinstalling 2.27 transfer gears from an FJ60 into the troopy...

The transfer input gear was very hard to insert into the gearbox shaft. Hitting on it with a hammer made me lose my nerve after a while. I tried to pull it out but it wouldn't budge! My gear puller was too short to reach, aaaaaagh, I need a larger puller! Tomorrow is a holiday here and the stores may be closed. So I tried the dumbest thing to do, I inserted a prybar between the stuck gear and the case.

PING! A tooth chipped from the gear and hit me on the right cheek. Another half an inch I could have gone to the ER with an eye injury.

The gear is now farked Measurements of the stuck one shows it is the same size as the original gear. The tooth count are the same at 32 also. But I still need to pull it out!

Any idea if the input gear normally takes that much force to insert on the gearbox shaft? It is still sticking out by about 7 mm. I just replaced the seal with a new one, but it can't be that hard, can it?

Dave

my gears just slide on a off. but the nuts were a prick to undo. i cant see what could cuase that problem excpet that you have the wrong gear or have put the middle gears on instead

Thanks, I have a bad feeling either the gear isn't meant to fit the case or the centre to centre distance between the input shaft and the idler shaft is different.

Dave

It turned out different spline lengths was the issue. The 1993 gearbox output shaft has shorter splines than the older ones and I was trying to mash the input gear splines into a solid shaft. Duhhh.

Once I used the correct gear it fits beautifully

Dave