Thread: Removing gearbox KUN26 Hilux

Hey team, this morning I was driving and as I pulled away from an intersection I shifted to 3rd gear and there was a thud and I lost 3rd and 4th gear. All other gears work fine and a bit of internet research tells me that the boxes in KUN26 hilux's are known for stripping the synchro gear on 3rd and 4th so I assume this is what has happened, I thought I noticed a little backlash on 3rd/4th when decelerating the last wee while.
I'm gonna pull the box out and try fix it. Any tips for removing one of these boxes? I took a look at it and I guess the easiest way will be to remove the cross member under the transfer box and take the transfer box off the back of the gearbox first. One problem I envisage is getting to the two bolts on top of the bell housing, doesn't look like much room to get to them, any ideas?
I have replaced gearboxes/clutches, done a new head on my old Ford ranger etc by myself before so I'm not a total noob when it comes to this stuff but never pulled hilux apart before.

They are a complex gearbox. Have a yarn to the guys at Lineside Auto in Rangiora.

Normally doing gearboxes I drop the gearbox cross member and jack the front of the motor, then use a few extensions and run them through to get to the top bolts over the top of the bellhousing. Just have to be careful of crushing anything running between the firewall and head.

What’s the cost of getting an exchange reconditioned gearbox?

Considering you may replace more than the broken gears it may be worth looking at.

I thought you were a farmer? Most farmers I know don’t have time to be splitting gear boxes.

hey Ryan -if its any consolation ,getting the friggin starter motor out of a 2L_TEcmotor aintthe bloody easiest job either ,soooooo might just have a wee think about coopers tip -in order to get at the top retaining bolt.Mines been off road for two years but she stillburasts into life under tow,so weve decidedafter numerous cliks -replace starter motor.
remember doing a clutch on my deceased Pathfinder -hua of a job even with four of us.all that weight bugga all room to move.

Originally Posted by Cooper

Normally doing gearboxes I drop the gearbox cross member and jack the front of the motor, then use a few extensions and run them through to get to the top bolts over the top of the bellhousing. Just have to be careful of crushing anything running between the firewall and head.

This is what we did to remove the one in the Bighorn to do the clutch.

Gearboxes come out easily. No need to raise motor or anything. The boxes are bloody heavy so be warned.
Take out in 1 piece with transfer case attached.
Remove gear levers from inside. rest is straight forward really.
Have done lots of clutches on them. Only ever had to strip a couple of boxes. But they had been raped and had destroyed gear sets.
Synchros only ever been a problem in gearboxes where the incorrect fluid is used I've found

Normally I'd get at the top bolts by removing the covers on the interior. Don't know of thats applicable for the KUN26R.

One thing I do know though, unless you're a specialist gearbox man, I wouldn't in a million years go into that box myself. There are that many specialist tools required for these gearboxes you'll get in there and then have a major tanty, that would be my bet. We ran a fleet of 100 of these vehicles on the mine and had a few gearbox failures from the extreme abuse they got, and despite highly qualified and competent (and very highly paid) mechanics, a gearbox overhaul was totally beyond the capabilities of the shop. They'd pull the box off, and send it away. I suggest you do the same.

Top bolts easy to get to with socket and extensions.

@Flyblown Aussie mechanics?

Originally Posted by ONYVA

@Flyblown Aussie mechanics?

From all over the world. Bit of everything. Why?