Technical 4x4 gearboxes

[andyholli]

After some fun rooting around inside to build and refresh my gearbox, I have a stack of bits left over.. Some early, some late.

If anyone on here is missing a bit or has damaged gearbox parts, let me know what you need and I'll try to help.

Equally, should anyone have spare 4x4 box bits that they're keeping 'just in case' (pun intended) - I'm interested in acting as a repository with a view to building good boxes for the community, from multiple not so good ones.

Cheers all.

 

[goodgirl156]

I have to admit, i'm impressed by the undertaking of this. Taking apart a gearbox scares me!

 

[Alixcompo]

Wow; I am also in the "Never strip a gearbox camp.

It's a black art where you have to sell you soul to the Devil.

I never had enough soul left after I traded it first time with the local pub.:worship:

 

[purple haze]

That's great...we have a gearbox guru...

 

[goodgirl156]

I have always thought, how hard can it be? but then had recurring nightmares about tiny tiny springs flying off in unfavemable directions to never be seen again.

 

[Dragon Man]

^ thats automatic boxes.. guhh..

when andyholli came around to deliver some parts for the grey panda, i had a chat with him about gearboxes.. i wish i kept my old 4x4 box now.

im still thinking of getting a new pair of 5th gears cut to be taller. just to take the strain of motorway travel off talon's engine. keep the other gears standard. if i do that though i may see about getting new syncros made up for 3rd.. out of something more.. than chocolate.

i do like the idea of this.. nice one man!

 

[aquamarine]

Yes please! I suspect I'll need some gearbox bits when the wheels of my Mk1 start rolling properly...and would like to discuss the soon-to-be-famous Holliday High Ratio Panda box...

 

[andyholli]

Bring the action - can't wait to begin the high ratio experiments Aquamarine. I may end up wanting one too.

Goodgirl's right about the springs- 3 little ones (one blue) with ball bearings on that all want their freedom. But the one to watch is the selector bias that pings across the garage as soon as you start to remove it. - Who'd have thought one of the specialist tools needed would be a towel..?

I think root cause is the big gaps between gears. Take time shifting (my father taught me to say "one, pause, two" in my head) or maybe a lightened flywheel to reduce rotational momentum could help bring down syncro wear.

..Soul? - Long gone, but its alright, I don't miss it.

 

[totnesmonster]

Hi all, been away from here for ages, the Panda's having a break for a little while...

I've built a high ratio 4x4 box, which works well, and have been meaning to stick a few pictures on here for ages, basically its a 4x4 standard gearset with a 2x4 final drive, layshaft and 5th gear

There are 3 5th gear ratios:

2wd have a 0.837 gear (the one I've used as the higher final drive more than compensates for the lower 5th ratio and makes it a bit easier on hills.

Early 4x4s have a 0.780 ratio (same as 5 speed Unos etc.)
Later 4x4s have a 0.731 ratio. This can be retro-fitted to an early box and should be doable with the gearbox in the car as it doesn't need complete dismantling of the 'box.

Couple of pics, showing the smaller (higher ratio) final drive, this needs the threaded holes drilling to fit to the 4x4 diff. Unfortunately it is hardened (seriously hard!) so needs a drill press with a pretty hardcore drill to do it. I trashed 2 tungsten carbide bits doing mine but got there in the end!

cheers,
Mike

 

[andyholli]

Quick update-

Our gearbox gaskets are all "no longer available" from Fiat. I've cut some new sets and will keep a master available so..

If anyone on here is doing a box refresh and would like a hand cut gasket or four to help them along, let me know.

If authenticity is important for you however, I must warn that only finest English, not Italian, gasket paper is used.

You can even choose your thickness!

 

[Dragon Man]

... Just to happens..

that i have come by a clean (jet washed) 4x4 box. with 153k miles on it.

its bex's box, apparently it has faults but seeing how i never drove the car due it being to.. "flexible".. i never managed to test it.

just wondering if you would be willing to have a peek inside, see if anything is up with it. i have a feeling that it has done a lot of miles with little to no oil in it.. when i tipped it about when it was off the car, before i cleaned it some horrid water.. oil mixture came out.

maybe has more water in it now its been jet washed but if the damage has been done.. its been done.

feel up to it, andyholli?

 

[andyholli]

Happy to John.
Drop it off anytime and I'll make you a cup of tea and show you around the projects.
Cheers.