Ford Cargo 0811 gearbox?

Could be various causes but any of them will more than likely result in a gearbox overhaul!
Check the oil in the gearbox. If it has an opaque green/grey colour, there is water getting into the gearbox - possibly through the gear linkage boot being torn etc. Water will also result in the synchromesh friction rings disintegrating - you may find bits of them in the oil!
If it's a 4 speed there is a 4-310, 4-310-S and a 4-410 -S.
Removing the gearbox is a fairly major job! The type of body on the lorry can make this more or less awkward. E.g. a tipper will give you access from above but a box body will restrict access from above. I removed a Cargo 4 speed gearbox in recent times. It is attached to the clutch housing by 4 bolts/studs (5/8" UNC as far as I can remember). Obviously you disconnect the gear shift linkage, tachograph drive cable, and drive shaft (4 off bolts 19mm wrench!). Also if there is any auxilliary equipment such as a PTO to drive a hydraulic pump for a tipper or crane etc this needs to be removed. (Note: drain gearbox oil first! - otherwise it will pour out of the side mounted PTO (if you have one)).
You need a transmission jack to support the box and then to lower it to the ground. Alternatively, an engine crane could be used - but only if you have access from above as mentioned earlier!
The actual overhaul would be best left to a specialist overhauler and they will usually remove the gearbox for you anyway - far easier than doing that bit yourself.
Re-fitting is the reverse of removal and the trick here is to get a length of 5/8 UNC threaded bar and cut it into 4 short lengths approx. 4 to 6 inches long. These should be screwed into the holes in the clutch housing to act as guides while the gearbox is offered up to the clutch housing. Make sure the clutch release bearing is on the right way round etc. Remove each threaded bar one at a time and replace with the correct bolt. All bolts should be torqued to the values specified by the manufacturer (given in Ford workshop manual). PTOs (side and/or rear mounted) and pumps go back on - note that you need a new gasket for these- and torque bolts. Reconnect tachograph/speedometer drive cable (on final drive), gear linkage etc and re-fill with correct oil.
All this is easier if you have a garage pit or 4 post lift.

JD
February 2008

so does mine - fingers crossed someone can advise.
are your brakes good ? mine are on or off so just replaced the lining, now i am having problems adjusting up

dave
February 2008