Transmission/gear issue, 62 Series iia 109...w/200TDI Defender Engine

[frmass]

Hi JP, thanks for the reply. Here’s what I’ve sorted so far since my last post...
-Took off the overdrive unit, no obvious failures, all turned smoothly, but inside the main (big) gear that connects to the output shaft of the gearbox was pretty gunked up, and the small teeth inside were warn but again, nothing obviously broken or chipped.

-With engine running, in neutral, output shaft from gearbox doesn’t spin. Same no spin in all gears except 4th gear. 4th gear, release clutch, spins like a top.

-Obviously with the overdrive removed the transfer case was sitting idle.

Thoughts?

[jp-]

Since there was no "bang" or other loud noise, I'm still thinking it may be something simple. Obviously, you have narrowed the problem to the gearbox and not the transfer case. The first thing I would check is to make sure that the shifter is actually doing it's job. Pull the top cover and shift knob off. Make sure that there is no excessive wear (some of the S3 shifters are very prone to wear at the shift ball). With the shifter out of the way, try to manually engage another gear other than 4th and see what happens.

It's very unusual that 4th would work and nothing else unless the problem is simple.