BRAMMER

iTrader: (23)

Basically anyone that's opened up or rebuilt a T5 box I'm struggling to get the tail section back on and I'm wondering if any special trick I don't know about, it slides on but stops about 15mm from being flush but sits of line with the holes so something on the inside is fouling any advice as it's driving me mad

gingerturbo

iTrader: (2)

It's not catching on the speedo drive is it or the pin for the linkage?

BRAMMER

iTrader: (23)

drive is out and so is the pin as i'm trying to put the rear part back on so nothing other than shaft and selector rod is poking though

gingerturbo

iTrader: (2)

Can you feel if its the casing or the shaft that catching, the drive may be out but it might be the worm gear catching

BRAMMER

iTrader: (23)

doesn't appear to be, i know theirs a small clip coming off the worm and i've tried to line that up - i'm not sure if it just needs a good whack but i'm worried that may damaged something

RIB1122

iTrader: (2)

it will be the 5th selector shaft not lined up

nixon_2wd

As above. Usually takes some doing to get it on correctly. I found that supporting the back end of the primary housing (right where the rear housing is mating to the primary) with a small hammer or punch or something to get it at an angle (tilted forwards) ease the guiding of the rear housing.

Also I noticed your other post regarding shifter position. Should be in neutral when you mount it on the case, then lube the shaft ( ) with some transmission oil before sliding the rear housing on.

BRAMMER

iTrader: (23)

Had a good look at it today, also read through some American forums to see if anyone else had suffered from this and seems quite common.

Basically really simple, give the 5th selector a light tap and and move the seletor rod to the right drops the gear down as it's sitting up at little, as soon as that was sorted the rear section fitted perfect.

Had a little issue fitting the selector block on after i'd fitted the rear housing so the housing needed to come off and sealer cleaned off - after a dummy run i worked out how to get it all back together.

Got it all built back up and sealed and all gears select