Technical Fifth gear on 2000 2.8 Motorhome

[Nickho6]

My fifth gear on my Autotrail Arapaho has gone, keeps jumping out. I have looked extensively on the internet and seen that it's easily changeable! At the weekend I took the fifth gear cover off and was presented with a nut that had been badly beaten with a screwdriver to get it on! I have tried all sorts less heating it to get it off to remove the synchro and the large fifth gear. The nut will not budge, does any one have advice or experience of removing this nut. I have flattened the tabs on the tab washer so that isnt the issue.

Here is and image of the nut and fifth gear etc for viewing pleasure...

 

[bugsymike]

Ouch, it looks like a blunt air chisel bit may be the only answer as no way are you going to get a correct tool on it.
If the nut wasn't so badly damaged you could probably have modified an old socket leaving four ears to drop in the grooves, but little chance of that.

 

[AsdaPricey]

Hello @Nickho6

I agree with @bugsymike - brute force put it on and likely will need the same to remove it.

Consider heat on the nut and freeze spray on the centre shaft - an agricultural engineer once showed me that way when I was struggling with removing several frozen studs and bolts on my then 1937 Austin Ruby - to raise a smile here’s a picture of it being driven by the dog, sadly both long gone.

An alternative removal technique If you can obtain a new nut, would be to carefully drill a line of holes into the face off the nut only and split the nut.

At least you’ve got reasonable access to it….

 

[bugsymike]

Another thought, not ideal but if two hammer and chisel wielders from opposite sides at the same time in same direction of undoing may provide an even force to release it.

 

[Eternal Optimist]

Assuming there's enough of the nut protruding out, would it be worth clamping a decent set of Stilsons onto it and giving it some beans with a scaffold pole for leverage?