Forum:
I have recently bought my 1st Foutrak a 2.8td G reg. The gears are very clunky when cold & difficult to get into 1st & 2nd gear but when it warms up they are much better. I have been told that all 4x4s are like that but I find that hard to believe. can anyone tell me if this is true?
Clunky gears
I'm afraid this is a well documented problem (on this forum anyway) which affects the fourtrak. It is caused by the mainshaft nut on the back of the gearbox coming loose and allowing the gears and synchros to move slightly up and down along the shaft. This stops the synchro hubs from doing their job, hence the clunking gears. The cure is to replace the nut and keep your fingers crossed the threads on the shaft are still OK.
clunky gears
Thanks for that. Is it going to do any damage while its like it? Ive had the Fourtrak for a month now & its no worse than it was then & I cant really get it checked for a couple of weeks.
mainshaft nut
only a demon buys a lemon!
Hi, i bought a right pup of a fourtrak for the first time too!
i have exactly the same problem on my 1990 !
could anyone tell us where to find this mainshaft nut? is it on the outside of the box? or expensively inside
only a demon buys a lemon!
If you look under the vehicle
If you look under the vehicle, at the gearbox/transfer case assembly, you will see a cast iron spacer, about 6 inches long, between the gearbox and the transfer case. The nut is in here. To get to it, drop both tailshafts, then remove the transfer case as one unit, basically, about 8 bolts hold it to the back of the gearbox. You need to split them between this spacer, and the back of the gearbox. When you remove the transfer case (careful, its heavy) you will see the nut up the top, about 24mm. It has a deformable flange on the nut, which, once tightened, you punch into the keyway on the shaft.
Its not a real hard job to do.
Growing old is compulsary, growing up isnt, and
MUD MAKES EXCELLENT TOOTHPASTE
Please visit http://groups.msn.com/AussieDaihatsuRocky/_whatsnew.msnw
Growing old is compulsary, growing up isnt.
MUD MAKES EXCELLENT TOOTHPASTE.
I use billion dollar satellites, to find Tupperware.
Please visit http://groups.msn.com/AussieDaihatsuRocky/_whatsnew.msnw
All views and advice offered are my own, from my ow
easy ????
only a demon buys a lemon!
EASY???? i dont even know which end of a spanner to hold mate!!
only a demon buys a lemon!
Mainshaft nut
I drove mine for 5 years just putting up with the clunking and not knowing how to fix it. It didn't get any worse but the threads in the shaft did get damaged. It cost £70 to get the old threads turned off, the shaft built up with stainless weld, re-turned and re-threaded. It really isn't that hard to do, just split the box from the transfer box and tighten the nut (its the uppermost one). Milner sells new nuts, or they are about £6 from Daihatsu I think. My dealer had them on the shelf so I suspect this is more common than Daihatsu admit.