URGENT...somethings jammed!

[Highlander]

It happens in 2wd so its not the front prop/axle

its not the transfer box as thats all turning freely

Its not the rear axle as it still happens with that disconnected

Thinking about it logically it must be either the gearbox or a seized/broken input shaft UJ?

Although the gearbox turns freely I'm assuming it must be in neutral when you turn it?

Therefore does the problem only appear once a gear is selected and you release the clutch to engage drive?

or with the gearbox still in neutral does it stick once its prop is attached? (must be the UJ)

[Darrell]

Rear wheel bearings OK. Just thought if the shoes have adjusted up the wheel may turn freely until the weight is on.
Just clutching at straws here, as I'm intrigued as to what it is.

[chris71920]

That all makes sense when its written like that

The thing is it was perfectly fine on the drive to workshop in 2wd, its literally only since fiddling with the drums and attempting to drive out of the garage that I noticed it.

It may be POSSIBLE but highly unlikely for the gearbox to die in that time considering what I was actually working on.

All UJ's seem free enough and no seizure has happened.

Yes rotating the box shaft by hand was with it neutral. It made the jolting, binding noise in 1st and reverse also.

Re: wheel bearings, I think I tried it in 4wd with the rear prop disconnected (only driving front wheels) and it still did it. Will double check tomorrow.

Also will try and get all 4 wheels off the ground to help with checking everything individually

Tomorrow I will try connecting it all up again (after checking its not the selector shaft alignment inside the trans box) and pushing it along while out of gear.

Is there any special order of connecting props etc?

[Highlander]

No, just bolt them on

Are your transfer case mounts and gearbox rear rubber mount all ok?

[chris71920]

I could seen them flexing a little when it was binding but not majorly, not really in a sloppy way anyway

[Highlander]

I think they would need to be completely gone to possibly cause something like you are seeing.

Is the gear stick selecting gears ok?

Sometimes the small gearstick locating bolt can shear off and drop down into the gearbox, that may also be a possibility, maybe just a bit of it has broken off

http://www.zukioffroad.com/Tech_Library ... fter.shtml

[chris71920]

Yes its selecting as normal, however even with it in "neutral" on the transfer box, it would still clonk and try to drive something. As far as Im aware nothing should happen (same as if its in neutral on the gearbox) So Im thinking it might be the same as what the link I posted earlier showed, with the shafts inside not being aligned properly and therefore not de-selecting drive completely to one axle.

Ill check the bolt also, thanks

[chris71920]

Think I've found the problem. The input shaft has a partially seized uj, it rotates one way but not the other. I've freed it a little but its not loose enough. Can't work out how to get it apart though :(

[Darrell]

Think I've found the problem. The input shaft has a partially seized uj, it rotates one way but not the other. I've freed it a little but its not loose enough. Can't work out how to get it apart though :(

Don't bother to try and free it up, treat yourself to a new one. If it's worn the rollers can jam and it can cause too much damage if it fails. There not expensive as you don't need to get one from suzuki.
Fortunately I have access to a bench press so no hammering for me.
http://www.suzukiclubuk.co.uk/diy/16-transmission.

[Darrell]

There's some info on th UJ's in the "stickies" that suspiciously looks just like the info I put on Difflock years ago
http://forum.suzukiclubuk.co.uk/vi ... 12/t,2250/

There's generally 2 different sizes 23mm or 25mm cup sizes.