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This was an old thread but I re read it and the thoughts I had were just use what you have and get air support for fuel, breakages etc! From the cost numbers thrown around for any conversion techniques it seems that air support would be a good deal cheaper?

The resistance on the peddle sounds like a similar event that happened to me, the issue I had was resistance on the clutch peddle that I tracked down to the clutch surface rusting and semi bonding to the plate. I didn’t press on the clutch peddle ferociously though, I had my wife put pressure on...

Yup it’s all back together already but that is what they did, a high quality synthetic grease, not sure what brand. On the road now south bound.

Well I think I am part of that club too! The only lube is the grease on the initial install until you split the transfer case and transmission apart again! I am almost convinced that the chunking was that spline set up skipping while under load.

Dan I don’t think so, I am pretty sure but not 100% sure but there isn’t any seepage onto that spline. The mating surface looks sealed though. Once the transmission was removed and looking at the spline it was relatively dry except for old grease mixed with metal bits as someone mentioned “crud”!

Here are a couple of exploded views of the transfer case, not very much help I found and really the only ones I found.

The mechanic seems to think it is wear, he had done many of the transmissions from the Other Fuso trucks that had bad transmissions some years back. I thought it was excessive wear myself from not enough grease but there was still some in there, particularly in the female end of the transfer...

Couple of pics, one on the right is what I’m calling the output shaft, left one is just a comparison of what it should look like mostly, it is the shaft from the transfer case.

Congrats! I’m coming up on my 14th year in 2024.

Thanks Dan, You were also saying something about up grading the gearbox, I’m not aware of any up grade items at least not here in North America, here we have a difficult time just getting parts! I would have liked to get a bit different gearing and newer less fragile syncros but right now I am...

The output from tranny into transfer case was very worn! Those splines were small pyramid nubs that were so worn out I want to say they were the cause of the clunking but I’m not certain. I am keeping every component removed from the whole works and I will try to upload some pictures of those...

Once they got the tranny out and opened up I decided to get it all done, as in all new syncros, all internal bearings, which I think there are six of them and the gears on the main shaft as well. Gears on the countershaft are ok. The splines of the output shaft were worn away to nubby mounds so...

They can get the parts ok by the looks of things, the output shaft is damaged from the bearing imploding which galled the shaft. While it’s all apart all bearings,seals,clutch stuff including the slave cylinder will be replaced etc. It will cost a bundle! I haven’t really heard much of any other...

Thanks for the suggestions everyone! Well it’s not good! The truck is at Kearny Mesa Truck Centre and the transmissions out, so far the output shaft is bad and a cluster of gears but not all certain yet. It just got pulled out yesterday afternoon. Owen, metal chunks on the magnet, so that...

Managed to limp back into the States and am busy finding a reliable towing company to probably get me to Kearny Mesa Truck Centre as it’s the closest one from me, definitely getting worse and don’t want to drive it! So far one company came back with $2000 US to go 160kms!

Yup, checked the mounts and other things but it’s the transmission. So far the mechanic thinks it’s the bearing in the tranny but obviously we haven’t gotten into it yet, seeing about parts.

Yeah you have a point there, I’ll focus on the transmission, thinking about the clutch plate too, original and a few miles on it!