HOW TO AVOID GEARBOX FAILURE

• On a newly-purchased vehicle (unless you have proof of good regular servicing) change gearbox and transfer box oil (and engine and axle oils) as a matter of course using the correct spec oils. Do this before using the vehicle in earnest or under full load. • Drain old or unknown oil, and check for metal particles using a magnet and torch. Golden synchromesh metal flakes are easier to see with a bright light, while the magnet will attract any broken gear teeth and swarf. • Conduct regular checks for oil leaks, including lifting the seat box centre cover for access. Grass and bare soil can hide the true extent of a leak, especially if the vehicle hasn’t moved for some time. • Oil from the bell housing area needs to be identified as either engine or gearbox oil, and appropriate action taken. • Ensure the oil breather pipes are clear and not crushed or melted along their lengths. • Listen for grinding, groaning and vibrating noises from the drivetrain and investigate as needed. Remove the centre seat box cover and road test the vehicle for additional clarity. • Don’t jump to conclusions, and don’t wish away a fault or drive through it. The repair bill will only increase. • Avoid rough use and abuse of the

gearbox, especially when off-road. • Always maintain the oil level, and change the oil annually using Dexron III ATF in the LT77 and the specifically recommended oil for other gearboxes.

LT77 mainshaft spline wear can result in sudden loss of drive, but has mostly been eliminated on rebuilt and modified boxes. It’s caused by a lack of lubrication at the splines in the transfer box and was fixed fitting the later cross-drilled transfer...