My D110 is going through some updates, 1 new Ministry of Defender A/C kit including new Puma Dash conversion. In this upgrade, we changed out the gear stick (the original would hit the new dash) and added the 'slick-shift' which cuts down dramatically the total movement between gears. This was done last summer and all worked fine in test drives. With the pandemic, our project was on hold for several months (trouble getting various other parts, etc)--so it has sat for 6 months without being driven. Now that we are back working on it, we went to back it out of the garage and it won't go into reverse and the reverse light also does not come on. I've backed out the reverse switch just in case it was part of the problem--didn't help.

While in neutral, the stick moves easily back and forth and you can 'feel' the gears only over to 1st gear. it will not go farther. With clutch down, you can put it easily into all other gears but Reverse position, again, won't go over that far to the left.

When I asked a few friends, they all point to clutch as a root cause but not how to fix it. I checked clutch fluid and that was refreshed a year ago, looks full, looks clean. clutch pedal 'feels' normal to me.

I am not a great mechanic and have learned by doing, getting help, reading and watching youtube... but everyone starts somewhere. Before I tear open the gearbox again, I'm looking for advice for what to look for and troubleshoot. But I am courageous and willing to do the work and learn.

Any advice? Where do I go next? I have a safety inspection due by EOM, so getting it driving is kinda a top priority [img]data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7[/img]

Thanks,
Scott

 

Sounds like something to do with the shifter you put in. Does the shifter allow you to put it in reverse if it is not running...or are you not getting enough lateral movement away from you to engage reverse? If it is not moving past 1st/2nd position, then l'd say shifter issue. Just pop the boot off and take a look to see if something is restricting movement.

Clutch really has nothing to do with allowing movement over to reverse position, it just allows the gears to mesh once you need reverse. Any if you have about 1" to 1" 1/2 top play on pedal...you should be good. Plus, you say it shifts fine in other gears.

 

See pics and videos. I had some success in moving the gear stick over farther after removing the reverse plunger. It did appear that the plunger, while does work, was hitting at a wrong angle and thus not moving. That said, when I tried to manually move the shift into reverse, it grinds as if the spindle is not stopping when clutch goes down. see video.

 

Sounds like you have a couple issues, clutch adjustment and reverse gear not moving into position properly.

lf the rover has been sitting for a long time, in a damp climate, the flywheel and pressure plate may have rust on them and the fiction disc isn't releasing totally. Maybe if you drove it a bit, through the forward gears...it would clean up the surfaces. You should have some "free-play" at the top of the pedal. This is from top position until you start to feel resistance, should be about 1" - 2" of free-play. If there is none, then the disc never releases totally and reverse gear is unsychronized...so without total disengaement...it will grind.

The shifter not moving the reverse shifter folk smoothly...is something else and could be from installing the slick shifter or something wasn't right on first install...and eventually showed up. I'd reinstall the old shifter and see what happens.

Good luck.

 

Ok, so another update. we reinstalled old gear lever without slic shift. Operates with similar issues as the slic shift eqp.
I think I have the reverse plunger in the right position now so gear shift can go to reverse position but still grinding. Living in Houston, the high humidity & sitting for several months makes sense for clutch plate rust & moisture. So my son and I backed it down our long driveway and into the street. Then drove around the neighborhood for 30 minutes running it through all the gears, even 5th. Everything was smooth, except Reverse still won’t engage. Posted a new video in the same folder as the others. We did check the fluid level and it took 1/3-1/2 quart to top it off. Not sure what to do next.

 

If it won't go into reverse, even with engine off...then l'm thinking something happen to your reverse gear pivot shaft fork/lever. Maybe just a coincide, that it happen after sitting for so long or happen during your last drive...but you didn't notice it, because you drove straight into the garage. For the fork to be restricted, says there's something internally wrong. Maybe the retainer that holds the shifter fork/lever onto the pivot shaft broke or loosen up?

The drain plug/filter basket are pretty good size, try draining fluid and look for material/chunks. Stick a magnet up through the drain hole and try to slide it along bottom of trans case...to see if you come up with any broken steel pieces.

Part of me says, you'll have to go in eventually...but l don't want to be the one to tell you that.

Sorry, l can't be more help.

Edit...the more l think about it and after studying the manual some more...it seems like it would have to be the main shifter fork shaft. Something, roll pin or something has shifted around or broke, causing the restriction into reverse.

 

Thanks. This is obviously not my mechanical sweet spot of skills and I appreciate all the help thinking thru options before having to crack it all open. What you suggest makes sense. I've not gone into this before, but I'm brave and want to learn. Since I need to pass a safety-only inspection this month, I'm going to see if they will pass it without a reverse gear. Either way, it's going to be a challenge as my garage does not have a high ceiling to raise up the truck more than another 1-2 feet. but there is always a way... I will post more as I learn more. Thank you - Scott