Let down

[disco 1 tdi]

Thursday night i was driving home from work enjoying the sun and thinking how reliable my disco had been and the posibility of a mini expedition later in the year!

Think i must of tempted fate, the Land Rover gods were not happy with me for whatever reason :( i pulled up at some traffic lights and as i went to pull away there was a horrible thud which was followed by a sickening grinding gravely noise. The clutch seemed fine and it felt like it was going into gear but as i lifted the clutch nothing  :shock: just the grinding deep graveling noise. all of which happend outside a highschool.

Anyway some friendly boys gave me a push into the school car park. then i made the call to my breakdown cover. an hour and a bit later dad turned up in his v8 90 and towed me 25 miles back to his. On closer inspection theres no obvious damage or oil leaks which makes me think gearbox. Has anyone else had similar problems?

Where do i need to start? guessing the engines gotta come out? any advie apreciated

Toby

[Frankie-Boy]

You might have blown a diff, try putting the centre diff in and see if it moves then.

[Saffy]

FIngers cross it what the man ^^^^^ says .........but disco1 though......... might be the input gear splines or worse the shaft itself. Early LT230 tranny had poor lubrication of the shaft splines, later ones had cross drilled input gears that allowed oil to reach shaft splines. https://docs.google.com/Doc?docid=dhfmtstj_0ghdpj7jh&hl=en

[disco 1 tdi]

Cool, i'll have a good read.

Im pretty sure that we didnt get drive in any gear inc props not moving

[disco 1 tdi]

all bar one bell housing bolt removed. the hardest one to get to has rounded 

any ideas??

[Saffy]

how come you taking gearbox out? hopefully not to inspect the input gear.... as you just need to remove the PTO cover on the back of the box and look inside - remove the retainer and the input gear will pull out.

Try hex socket instead of crappy multipoint sockets on the bolt head.

[mark-d]

does it do it in both high and low?

[disco 1 tdi]

yeah just no drive

[Disco-Ron]

I think you've been a bit hasty to take the entire gearbox out, it is a guess possible for it to be the input shaft into the nain box that has gone, butas said, most likely the intout into the transfer box.... which is a much simpler job!!

It pasy to research things fully before you get your spanners out, esp on something as awkward as taking a disco g box out!

[Dr Neil]

Where abouts are you located??

As was suggested did you try engaging difflock and see if you have drive??

[disco 1 tdi]

yeah thanks for the advice,  :clap:

[disco 1 tdi]

hi dr neil, did try diff lock and there was no drive

[stretchy]

hes right in takeing the gear box out if there is no drive in all gears and no props moveing as both in and output shafts needs to be cheked. sounds to me like the output shaft chap I have had this hapen twice to me now both on lt77 its no good just replacing one you need new out put and input ring on the t box as both will have damage  ... before it went was there an bit of a clunk when taking up drive or sticking it in reverse ???

stretchy

[disco 1 tdi]

yeah more like a bang than a clunk  :shock:

figured it would need to come out either way but now got a bolt rounded right at the top of the bellhousing close to the bulk head.

Sure we'll figure something out. am toying with the idea of keeping the disco for parts and transfering engine (i know its not straight forward, will need differnt mani etc)
into a 90 if a can find a subitable one ie, cheap

[les baty]

hi, i had a mate round off the top bolt on my disco, i got it out by hammering a smaller socket on to it, a bit barbaric i know but it got over the problem, also i never replaced the top bolt and never had any problems

[stretchy]

cheap 90 ?? good luck with that lol... hmmm my advice on the rounded nut would be to remove the cross member on the gear box and lower it down on a jack this will cause the engine to tilt back slightly giveing you a bit more room at the top. I would then try and get 1 size smaler socket and hamer it onto the rounded nut. this may damage the socket so dont use one out of your best set. I have a big box of odd sockets that I use thease for and normaly this works. yes im prety sure its the out put shaft.

[disco 1 tdi]

its crazy the kinda money they hold, phoned up bout a few today. surprise surprise gone in no time. Im gonna attack the disco again on sat if the weather holds out. I will prob give the socket and cross member idea a go.
 

[Dr Neil]

Where are you located??

[disco 1 tdi]

norfolkshire

[Dr Neil]

Sorry mate a bit too far for me to pop round and help, good look though.....

[disco 1 tdi]

cheers anyway,

[les baty]

just keep an eye on the pipes and wires on the bulk head when you remove the cross member and lower the box, there isnt a lot of room behind there and the engine will touch the bulk head when the box is lowerd

[disco 1 tdi]

Attackd the disco at the wkend, got the transfer box off and it turns out my output shaft is missing most of the splines! 

Also this seems to have created a pretty evil grinding paste and mullered the inside of the input gear. The next step will be to remove the engine. its now stripped, alternator, wiring loom, pas pump etc to try and make it a bit easier. Dam that bolt!

Am planning on rinseing the transfer box out, can anyone recomend a subtable liquid?   

recon box is on the cards, most likely ashcroft.

Target is to have it back on the road for billings

[Saffy]

There you go I scored with the diagnostic *clap* Could have fault found that with removal of the pto cover and 20 minutes effort at most. Good luck with the repair. Rinse box out with paraffin maybe - what I'd use start with anyway, replacement cross drilled output gears are peanuts for most boxes.

[disco 1 tdi]

yeah you right could have told from taking that off but it would have to come out anyway, i will be getting one of the newer gears with the oil holes  :D pitty LR didnt think of that first time round.

[Saffy]

yeah you right could have told from taking that off but it would have to come out anyway, i will be getting one of the newer gears with the oil holes  :D pitty LR didnt think of that first time round.

whats the mileage on it anyway, seems like it lasted a long time. They released a mod with a plate to splash oil into gear supposedly, dunno if it was a recall though. No need for the expense of an ashcroft box though. plenty of low milage boxes L230 out there from breakers and the likes. I got a disco box on my defender from a D2 td5 low miles for about 50 quid, took a while in the yard to find one with both low box and difflock on though as they removed it on later d2's.

[disco 1 tdi]

112K i bought it at 85K was in very good condition, has had all oils change reguarly since

[disco 1 tdi]

Got the box seperated from the engine today  managed to pull engine forward enough to chisel the rounded nut at the top of the bell housing off. jacked the car up a bit and pulled the gearbox out, piece of cake. just a big clean up job now, a fair bit of oil about (will change crank oil seal).

[disco 1 tdi]

Got my new box yesterday, superquick service from ashcroft, Much appreciated! Looks great and cant wait to get it on  :dance:

Pitty still waiting for the flywheel bolts from rimmer, !!!

Anyone used a britpart HD clutch before, read a few bits about differnt clutches inc borg and beck (now ap?) and seems they either go pretty quick or last for ages.

Iterested to know what the standard clutch was? The one that came out was Valeo looked pretty good

[les baty]

ive used valeo before and never had any problems, while its all in bits weld a washer on to the clutch fork where it pivits in the bell housing, its quite common for them to fail and you dont want to be pulling it all apart again to fix it