Loud bang, dead rover - transmission?

[SafeAirOne]

Nick, here's a good page for you involving overhaul of the OD. I didn't read the whole thing but it should say how to disassemble the OD:

http://www.nickslandrover.co.uk/archives/582

[Apis Mellifera]

Am I still right to think that I can get the factory part, ditch the OD and be running again?

Yes. You'd need the pieces the PO removed when he installed the OD. Basically a large gear and the black piece pictured below:


You could rebuild it and be pretty close in price to a second hand OD. I have a few pictures of an extra OD I have that show what your broken parts should look like:

http://smg.photobucket.com/albums/v307/dandomatic2/

[NickDawson]

You could rebuild it and be pretty close in price to a second hand OD. I have a few pictures of an extra OD I have that show what your broken parts should look like:
http://smg.photobucket.com/albums/v307/dandomatic2/

Sooooo that thing in the picture above? Just mail it to me, ok? You're a pal!

Nick, here's a good page for you involving overhaul of the OD. I didn't read the whole thing but it should say how to disassemble the OD:

http://www.nickslandrover.co.uk/archives/582

Great site - good find SafeAirOne - Going to give the rebuild a shot - got nothing to lose at this point

[Apis Mellifera]

Sooooo that thing in the picture above? Just mail it to me, ok? You're a pal!

I could do that, but only if you pay me with a two-party, out of state, bad check.

[Nium]

Fairey Overdrive Manual

A copy of the Fairey/Superwinch overdrive manual can be printed out or downloaded from RDS. Copy of the link...

http://www.faireyoverdrive.com/guide/page1.htm

If that doesn't work go to...

http://www.roversdownsouth.com/about.htm

and click on "Fairey OD Parts" under "Misc. Parts" lower left side of the screen. The manual shows the plate and gear that are removed from the transfer case and which are replaced with the gear for the OD.

[NickDawson]

What's the best way to get the broken gear off of the main shaft? Apis mentioned it going on with a hammer and chisel - is that the best way to reverse it too?

I;ve got the entire OD soaking in petrol now - going to go clean it up and start pulling it apart as per the guides posted above.

[Apis Mellifera]

The hammer and chisel is the wrong way to do it, but it's still done that way. In one of the pictures I pointed to the gearbox output shaft nut. It requires a special socket to remove (properly) and to refit (properly). Bend the tab out on the retainer washer, remove the nut, and then pull the CS off. It might be stuck on there so a little light prying may be necessary.

[SafeAirOne]

What's the best way to get the broken gear off of the main shaft? Apis mentioned it going on with a hammer and chisel - is that the best way to reverse it too?

The hammer and punch works but it is cartainly not the BEST way to do it. I've done it both ways and have found that the best way would be to use the (rather pricey) socket:

http://roversnorth.com/store/p-5705-tool-gearbox-mainshaft-series-ii-iia-and-iii.aspx

[NickDawson]

Thanks again guys!
I went with the chisel and hammer b/c it is what I had. Found the retainer ring too - didn't realize it was there.

I started working on disassembling the OD. I ran out and bought some ring pullers. The ones I found at Lowes just weren't up to the task of pulling the clips on the OD. I did de-grease the input shaft. Its odd, Its clear that the teeth have some pits and damage, and I found metal shards...but they still feel pretty sharp and have good depth. I'm fairly sure that this is the problem, but its amazing that such little damage caused the entire system to fail.

The prices for the RDS replacements are pretty steep - thinking about going back to the factory gear setup for now and rebuilding later. Its unclear to me what I need from the RN site. Any thoughts?

Here's the clutch and gear from the main output shaft - same story. Teeth have depth and are sharp, but also clearly damaged. You can zoom way in on flickr and see the detail.

[Apis Mellifera]

The teeth shouldn't be sharp. They are square cut sort of like smaller versions of the gearbox output shaft splines. Looking at the larger pictures, it appears that most of the damage is to the OD input shaft.

[BackInA88]

As bad as this looks the mating part in the overdrive looks worse.

Looking at the link to the pictures you posted.

[/QUOTE]

[SafeAirOne]

As bad as this looks the mating part in the overdrive looks worse.

Yeah--I'd like to see what the female splines look like with all the grease off of 'em--These on the male bit pictured are wasted!

[Bertha]

better off with high ration transfer box or high ratio diffs,

Yes, that way you could pound out the bearings on your engine instead

[Jeff Aronson]

Nick,

The overdrive feature is nice - one of my Rovers has one and one does not - but it's not mandatory, even for highway driving. The overdrive did not become available for Land Rovers until the Series III and it was an authorized option to help improve gas mileage. The improvement is in the 2-3 mpg range, meaningful at $8-9.00/gallon, but less so at $3.00 per gallon. Yes, you can reduce engine rpm at 60-65 mph through the overdrive, but what usually happens is that we peg our Rovers to the floor anyway and just go faster, negating the advantage .

Why not just get a final drive gear and end case for you Series III and try it for a while without the overdrive? Then you'll know whether the price for a rebuilt one is worth it for you.

BTW, are you running 15" or 16" wheels on your Rover? Just moving up to 16" wheels helps achieve some of the benefits without an overdrive.

Jeff

[Bertha]

Why not just get a final drive gear and end case for your Series III and try it for a while without the overdrive? Then you'll know whether the price for a rebuilt one is worth it for you.

Nick
I have to agree with Jeff. Your best bet may be to obtain the original trans gear and cover, just to get going again, and remove the overdrive for now. You may find that once you dig deeper into the overdrive, that the cost of rebuilding it may be prohibitive. Your best bet is to ship it to RDS for a free evaluation.