Blown hilux gearbox pictures!

[yamaha__308]

Hi everyone,

Pulled down my gearbox down last night, a blown 5th gear.
Took some piccys of the carnage..

What do you think?

http://i218.photobucket.com/albums/cc302/yamaha__308/DSC09379Custom.jpg

http://i218.photobucket.com/albums/cc302/yamaha__308/DSC09378Custom.jpg

This is the carrier for the mainshaft bearing, i think some goose has bent up a larger carrier so that it fitted in..:mad:

http://i218.photobucket.com/albums/cc302/yamaha__308/DSC09381Custom.jpg

[Tree cutter]

The crook bearing caused the gears to strip. When the bearing cage comes off like that it lets all the balls fall to one side so the shafts can push apart and let the gears climb over each other so they break. It looks like there has been too much load on the bearing which has caused the two halves of the cage to let go. It is repairable but it could be costly. New layshaft, 5th gear and a set of bearings and she should be as good as new.:thumb:

[brokelux]

dont look like 5th gear to me mate thats what some people call 4th gear although 4th gear doesn't actually exist thats looks like ya input shaft and main cluster gear to me

[ozrunner]

Yep brokelux is correct.

Its the cluster gears, which means its all over, as you will need a complete new shaft as these gears are irreplaceable.

[Urshtnme]

I think she's shagged!

[mac25]

are you sure you can focus on it :)

[yamaha__308]

Cheers fellas.
I just assumed it to be fifth gear as that was the gear i was in before the noise and it all came grinding to a stop..

The crook bearing caused the gears to strip. When the bearing cage comes off like that it lets all the balls fall to one side so the shafts can push apart and let the gears climb over each other so they break. It looks like there has been too much load on the bearing which has caused the two halves of the cage to let go. It is repairable but it could be costly. New layshaft, 5th gear and a set of bearings and she should be as good as newThanks tree cutter, i didnt think someone would be that silly to bend up a new cage.. Too much load the bearing? Like me towing in 5th sorta load? I just dont want it happening again.. Or is it just old age?

dont look like 5th gear to me mate thats what some people call 4th gear although 4th gear doesn't actually exist thats looks like ya input shaft and main cluster gear to meI was able to get drive in 4th and no noise? How does this work? I know 4th is straight through drive but i cant work it out..

Anyway, I've got another gearbox ready to go in after i find a new clutch, i was just curious to see how it all worked inside..


Its the cluster gears, which means its all over, as you will need a complete new shaft as these gears are irreplaceable.I was thinking about rebuilding this gearbox as a spare, but i spose thats pretty much out of the question..

are you sure you can focus on itFocus on what?

Thanks guys, it was a interesting exercise anyway...:thumb:

[HDJ105]

Yep brokelux is correct.

Its the cluster gears, which means its all over, as you will need a complete new shaft as these gears are irreplaceable.

Sure?

If that is the input shaft poking upwards in the first pic, I think you'll find the smallest gear on the mainshaft is 1st! ;)

The cluster gear or layshaft is the distant gearset in the picture, and yes the one that mates with 1st gear is buggered, rendering the whole lot useless.

[Tree cutter]

The gear on the right is the input shaft as Brokelux said and it should just lift off from the other gears on the mainshaft. 5th gear is below the carrier plate, and you can't see it on the photo.

[brokelux]

yamaha 308 if u look closley at the way u select 4th gear u will find that 4th gear locks the input shaft directly to the output shaft there is actually no gear as such heance the drive doesnot go through the cluster shaft even tho it is still spinning but not actually doin anything

[brokelux]

Sure?

If that is the input shaft poking upwards in the first pic, I think you'll find the smallest gear on the mainshaft is 1st! ;)

The cluster gear or layshaft is the distant gearset in the picture, and yes the one that mates with 1st gear is buggered, rendering the whole lot useless.

yes mate i'm sure i'll think u will find first gear is the largest one on the mainshaft and the smallest one on the cluster located just next to the sandwich plate in the pic

[yamaha__308]

Thanks guys, i had another look and a bit of a play around with it, think i understand now.
Heres another photo at different angle.

http://i218.photobucket.com/albums/cc302/yamaha__308/DSC09384Custom.jpg

So 5th gear is the ones on the right of the carrier plate?
So what actually caused this was a buggered bearing and not towing in 5th?
Do you know which gear the wrecked one is? (on the far left)
And finally, do you think it is worth rebuilding? Can i just get new bearings and the 2 gears on the left, or do they sell as a set?

Thanks again for the advice

[ozrunner]

So 5th gear is the ones on the right of the carrier plate?

Yep and both are removeable and replaceable.

Its your cluster gears that have broken and they form part of the shafts.

[ice_spy]

cut off your front input shaft and keep it as a clutch alignment tool. :thumb: