4 speed 2nd gear failure

[copernicus]

Hi Guys,

Just after a bit of tech advice from some of the gurus here.

I've got a problem with 2nd gear on an FJ40 LC.

The vehicle is a 1975 FJ cruiser with factory 4 speed and an Aussie V8 (similar to a Chev engine).

The issue I'm having is changing from 1st to 2nd or changing from 3rd to 2nd. When attempting to change gears, the shifter will not move into 2nd gear position. It can upon forcing quite firmly, or at very low RPM drop into gear.

When stopped, the gearbox can move through the gears smoothly.

I've tried some thinner gearbox oil (was suggested to try 50% auto transfer fluid). I've also tried adjusting the clutch. Neither seem to yield any success.

Do the gearbox gurus out there have any thoughts what else I could try?

Cheers,
Mike

 

[bogus one]

Did you recently have the top plate off?

sounds like shift fork mis-alignment

 

[Pin_Head]

It sounds like the clutch may be dragging or not releasing completely. Does it grind going into reverse when stopped?

 

[inkpot]

Howdy! Worst case scenario is that the syncro on second is worn out. John

 

[copernicus]

Thanks for your help guys.

bogus one: no, the top plate has not been off. I should have mentioned that I did change the transfer as the case developed a large crack! The issue appears to have started at the same time as putting on the new transfer. I was unsure whether this might have been related to the gearbox not having oil in it for a period (perhaps 1 month); or some kind of extra adjustment required with the transfer. Perhaps it was just coincidence that 2nd gear was failing at the same time.

Pin_Head: I initially thought it might have been the clutch. There is no grinding when changing to reverse. I have tried adjusting the clutch lever arm through it's complete range of adjustment (with the slave cyl pushrod) and it does not seem to make a difference.

 

[Pin_Head]

If it started when you changed the transfer case, I would consider the possibility that the case is assembled incorrectly on the transmission output shaft. Maybe you have the wrong spacers in the wrong order or something like that.