Mud-club

Vehicle & Technical => Discovery => Topic started by: Pablo011 on July 27, 2012, 16:22:04

Title: Gearbox swap
Post by: Pablo011 on July 27, 2012, 16:22:04

Now sourced a gearbox and should b e picking it up tomorrow but are they hard to fit or is it relatively easy ish to fit I think its just the box and not the transfer box so it is a weekend job ??? any thoughts


Thanks

Paul

Title: Re: Gearbox swap
Post by: lambert on July 27, 2012, 17:05:09

Took us a day to do a disco clutch without taking the boxes out at my man's mot lane. So on your back on a drive, start now and you may get Sunday evening for a test drive.

Title: Re: Gearbox swap
Post by: Pablo011 on July 27, 2012, 17:22:26

Sounds like my kind of weekend on my back under a nice young wo...........oh sorry right mmm if and when I do it is it possible to just take out the gearbox or does the transfer box have to come out as well as I am only getting the gear box not both ????


Thanks

Paul

Title: Re: Gearbox swap
Post by: lambert on July 27, 2012, 21:11:41

Take the t box off the main box first or it will kill you if it lands on your chest as a combo. Also replace the clutch as a matter of course, best bet there being a genuine kit and upgraded release fork.

Title: Re: Gearbox swap
Post by: Pablo011 on July 27, 2012, 21:24:57

ok so t/box first then the gear box. and replace the clutch as well....seems simple enough I mean "how hard can it be"???

Paul

Title: Re: Gearbox swap
Post by: lambert on July 27, 2012, 21:35:06

"oh god, he's got a power tool"

Title: Re: Gearbox swap
Post by: Pablo011 on July 28, 2012, 16:45:21

OK got my new to me gearbox from Mac4x4 thanks guy and great to meet you and your good wife thanks for the brew x anyway my gearbox fitter (my daughters boyfriend) has asked about getting a gasket set for the box's is this right are there gaskets that I need ???

thanks

Paul

Title: Re: Gearbox swap
Post by: lambert on July 28, 2012, 16:59:58

Err I don't think so but I dunno.

Title: Re: Gearbox swap
Post by: Dr Neil on July 28, 2012, 20:17:22

No gaskets required, but might be an idea to replace the output shaft seal between the gearbox and transfer box. If you jack up the truck you can get the gearbox and transfer box out in one. i always use a big ratchet strap looped over the chassis and under the gearbox so if it slips off the jack it won't land on you.
If you know what you r doing it can be done quite easily in a day and its best to get a friend to help.

Title: Re: Gearbox swap
Post by: Pablo011 on July 28, 2012, 20:21:12

Thanks guys also just noticed that there is a bit of play in the input shaft thingy is this very bad or just gonna be noisy ? and/or can it be fixed easily? its the shaft that goes into the clutch/flywheel from the gearbox

Thanks

Paul

Title: Re: Gearbox swap
Post by: Dr Neil on July 28, 2012, 20:28:38

when you say "play" is that up and down, in and out or side to side??

Title: Re: Gearbox swap
Post by: Pablo011 on July 28, 2012, 20:37:39

I can get hold of the shaft and give it a good ish alround wriggle, but not in or out just sort of round ish

Paul

Title: Re: Gearbox swap
Post by: Dr Neil on July 28, 2012, 20:58:08

there is usually a small amount of play in the shaft, once it is fitted to the engine the shaft sits in the spiggot bearing in the flywheel so can't move then.

Title: Re: Gearbox swap
Post by: Pablo011 on July 28, 2012, 21:15:44

Thanks Doc, I thought if it goes into the flywheel etc then it cant move about then so I think its nothing to worry about, but just noticed again god I am slow at this but its a LT77 and not a R380 so apart from reverse being the wrong way round it will fit to my 300 tdi engine ok wont it ??

Paul

Title: Re: Gearbox swap
Post by: Dr Neil on July 30, 2012, 14:05:59

I don't know, sorry..

Title: Re: Gearbox swap
Post by: lambert on July 30, 2012, 15:13:27

R380 boxes fit 200tdi's so at a guess the other way should fit too. Oh and unless it is an lt77s it will be lots less robust than an r380.

Title: Re: Gearbox swap
Post by: andyb on August 02, 2012, 09:06:03

Sorry just seen this thread.

Yes I know for a fact that LT77 and R380 are interchangeable behind a Tdi in a Discovery

If you only have the main box then just swap over the transfer box and away you go. If it is as a complete unit then swap the speedo sender housing and handbrake setup (just two rings of bolts that are the same on both 'flavours') I have personally done both combinations of boxes and engines, if you see what I mean :)

Title: Re: Gearbox swap
Post by: Pablo011 on August 05, 2012, 08:10:41

ok thanks guys, that's another job need to do, and for the record I have tracked down NWT Transmissions who say they can recondition the 2nd gear crunch syncro all for £210 if you can get the box to them, or else it will be £500 plus for them to take the box off rebuild etc so could be worth a look when i fit my other box to get my older one rebuilt and sold on..................or kept just in case .......!!!

Paul

Title: Re: Gearbox swap
Post by: lambert on August 05, 2012, 08:31:35

If it were me I would put in the lt77 as a temp mobility whilst I had the r380 re built, they are a much nicer box, and put it back in the car.

Title: Re: Gearbox swap
Post by: Pablo011 on August 05, 2012, 08:41:57

Thanks lambert, they say it will take approx 24-36 hours turn around, so could wait for it to be fixed then fit the original repaired r380 back in but that does leave me with a lt77 box ....

Paul

Title: Re: Gearbox swap
Post by: lambert on August 05, 2012, 10:23:56

Mudbay it? Or better yet use it as the basis of a challenge truggy.