Rover Gearbox - Fault Diagnosis
Rear drive output and transmission brake
Front drive output shaft housing
Insufficient oil or SAE 90EP oil not used; When
in neutral - wear in primary pinion bearing, constant
mesh gears or layshaft bearings; In all gears - worn
speedometer gear, worn primary pinion or mainshaft bearings;
All gears except 4th - constant gears or layshaft bearings
worn; In one gear only - worn or damaged gear wheel.
Transfer box - Insufficient oil or SAE 90EP oil not
used; intermediate gear has excessive endfloat ( should be
0.1 - 0.2mm); worn bearings; excessive endfloat of output
Over filling; loose or damaged drain/level plugs;
joint washers wrongly fitted, damaged or missing; damaged
or poorly fitted oil seals; cracked gearbox casing. Between
gearbox and clutch - worn or damaged seal in clutch withdrawal
unit. Between gearbox and transfer box - worn oil seal
Difficulty engaging gears
Forward gears - gear change mechanism incorrectly adjusted;
clutch spinning or dragging; clutch plate sticking on pinion
shaft. Reverse gear - selector stops incorrectly adjusted;
bush loose in gear; reverse gear seized on shaft. Four
wheel drive - locking pin seized in casing; broken selector
shaft spring; selector shafts sticking.
Difficulty disengaging gears
Forward gears - faulty synchromesh; damaged mainshaft
splines. Reverse gear - reverse gear seized on shaft.
Four wheel drive - spring for selector shaft missing
, broken or wrongly set; broken selector shaft spring; selector
shafts sticking; front vs rear tyres incorrect or excessively
Jumping out if gear
High range - transfer gear lever rubber boot not fitted
correcty; weak or broken selector spring.
Low range - transfer gear lever rubber boot not fitted
correcty; weak or broken selector spring; intermediate gear
has excessive endfloat ( should be 0.1 - 0.2mm); incorrectly
assembled transfer selector fork (fork should have threaded
side of pinch bolt hole towards centre of the box).
Difficulty selecting first
If reverse sected easily then reverse stop is not