Sorry that I have not been around for a while. I have been receiving
the posts from time to time but we have been busy travelling the world
over the last couple of years and latterly been away in the Troopy.

As for the gearbox/shaft problems. I believe ALL Troopys made from
when the 78 series were introduced to sometime in 2003 have the 2
piece shaft and all WILL have the problem. It seems that the problem
does not appear until 150,000 to 200,000km but I will not be
respnsible if your shaft goes earlier. YOu will get a clunk in all
gears gradually getting worse whe n changing gear.

Since we have ours repaired, there are still clunks but not so
noticeable and not so often.

When the splines give out, there is no drive at all - OK for us 200m
from home but potentialy life threatening in the middle of a desert.

Your choice what you want to do and when but I would have my gearbox
checked before a desert trip or any trip where it would be a major if
it went. As a bonus, we got a new heavy duty clutch fitted even though
the old one was only half worn at around 170,000km.

Total cost by a mechanic was from memory approx $3000 incl clutch.
Double for a Toyota dealer to do it unless it can be a warrenty claim
- some food for thought on this one as it is a common problem, we did
not have time to even talk to Toyota about it, we had to get the truck
on the road and doen to Melbourne when we had ours fixed.

We now also have a 2000 Rangie Vogue (not for long trips) to keep the
Troopy happy at night sharing the same garage. It is interesting
comparing the 2 vehicles. Cost to run per km is about the same (petrol
cheaper then diesel, the Rangie is better on the soft sand (wider
tyres???) but have not used it off road anywhere else yet. It will
never replace the Troopy though.

Stevesub


--- In troopyoz@yahoogroups.com, "Frank and Ros" wrote:
>
> Is there a difference between the 1999 78 series and the 2000? I thought
> they were exactly the same.
>
> -----Original Message-----
> From: troopyoz@yahoogroups.com [mailto:troopyoz@yahoogroups.com] On
Behalf
> Of Stephen Parkes
> Sent: Sunday, 21 May 2006 4:16 PM
> To: troopyoz@yahoogroups.com
> Subject: RE: [troopyoz] Re: dreaded gear-box dramas
>
> If you notice the problem seems to happen to early 2000 models
onwards so
> maybe we with earlier models are safe
>
>
> >From: "Frank and Ros"
> >Reply-To: troopyoz@yahoogroups.com
> >To:
> >Subject: RE: [troopyoz] Re: dreaded gear-box dramas
> >Date: Sun, 21 May 2006 06:57:19 +1000
> >
> >Hi,
> > Is there some way to check whether this gearbox condition is
> >developing
> >other than getting a clunk? I have a 1999 78 series with 95,000 kms
up and
> >I
> >don't have any apparent symptoms. The Troopy had done 64,000 km when I
> >bought it, so there's a bit of a chance that a new shaft had
already been
> >fitted.
> >
> >Can I test for play somewhere? Is there any way to see whether a
new shaft
> >has been fitted without stripping the gearbox down? If this thing
is going
> >to fail down the track, I'd just as soon have the new shaft fitted now.
> >
> >Cheers Frank.
> >
> >-----Original Message-----
> >From: troopyoz@yahoogroups.com [mailto:troopyoz@yahoogroups.com] On
Behalf
> >Of Tony Christian
> >Sent: Saturday, 20 May 2006 8:10 PM
> >To: troopyoz@yahoogroups.com
> >Subject: [troopyoz] Re: dreaded gear-box dramas
> >
> >Dave,
> >
> >I have a 2001 Troopy which had at the time about 80k on the clock.
> >
> >I too heard the same noise on take off etc.
> >
> >Fortunately I have extended warranty and had the job fixed.
> >
> >At the time I did some research and came to the same end as you and
> >Toyota have a modified shaft which they now use which overcomes the
> >problem. As I see it, it is a problem of dissimilarity of metals.
> >
> >My Troopy had done some "hot miles" meaning some long runs at 80/90kmh
> > down to Adelaide and for me crossing the Nullabor a few times. So a
> >large percent of my kms have been in 5th. Even with this mine
> >succumbed to the same demise.
> >
> >At least with Toyota there is a fix albeit expensive, with my previous
> >vehicle, whose name has been banned from my mouth " Land*****" I just
> >could not fix it at all!.
> >
> >Since I had mine done all is well on the gearbox side, infact the
> >Troopy just does its thing and even at 3.6 tonne on my desert trips it
> >is still fine.
> >
> >Just remembered, when we took the 'box out, the flywheel and clutch
> >still had machine marks on them so we did not have to replace them.
> >However we did the thrust race.
> >
> >Tony C
> >WA
> >
> >--- In troopyoz@yahoogroups.com, "ggoellnicht" wrote:
> > >
> > > --- In troopyoz@yahoogroups.com, "David Shelton" wrote:
> > > >
> > > > G'day All
> > > > First post in a while for me - moved to Sydney and the job change
> > > has kept me very busy!!!
> > > >
> > > > As several before me have noted - my Troopy finally succumbed to
> > > the dreaded output shaft problem common to early 2000 models
onwards.
> > > I noted a small "clunk" emerging at take-off - kind of like normal
> > > transmission take up - but more metallic and ominous sounding. My
> > > Troopy is a 2002 model camper with 170k on the clock. Given this
age -
> > > it was highly likely it was fitted with the weak two piece output
> > > shaft (spline with a sleeve).
> > > >
> > > > As time went by the clunk got worse, and started occurring in
> > > higher gears....
> > > >
> > > > I was planning a weekend of serious off-roading (last weekend)
- so
> > > took preemptive action and took it back to my mechanic friends. End
> > > result - new output shaft required. I have kept the old one - I can
> > > move the sleeve with my bare hands - and the teeth were reduced to
> > > razor edges - not long left... Unfortunately it got worse for me - I
> > > knew my clutch was on the way out but I thought I had a bit left....
> > > Not so - the clutch needed doing also. I knew this as it was
slipping
> > > a bit on really steep boat ramps with the boat on - but both jobs
> > > together.....
> > > >
> > > > So - new output shaft, bearing kit as the bits of metal would have
> > > gone all through the transfer, new clutch - plus the service it was
> > > due for....
> > > >
> > > > Gulp..... $2500! I know this is a good price given the work that
> > > was done, and the mechanics are mates so I know they did it right -
> > > but still - the credit card nearly blew up!
> > > >
> > > > Apparently when they were ordering the shaft, they said the Toyota
> > > people were having trouble getting the shafts because there was such
> > > demand!
> > > >
> > > > So - on this list - how many have experienced this problem? I know
> > > Steve S did a while back - anyone else?
> > > >
> > > > Cheers
> > > > Dave
> >snipped
> >
> >
> >
> >
> >
> >
> >
> >
> >Yahoo! Groups Links
> >
> >
> >
> >
> >
> >
> >
> >
> >
>
>
>
>
>
>
> Yahoo! Groups Links
>


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