03 L322 TD6 gearbox issues

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Gearbox stripped tonight, valve block excluded there’s not that much to it really, worlds toughest circlip was a disappointment, tyre lever a mini pry bar and a big screwdriver took maybe 5 mins being carful I defiantly wouldn’t pay £200 for the big locking pliers! Don’t know the names of all drums but forward coast one been hot though not welded, last plates with less external teeth burned and wavy but not sure if they meant to be or not yet! Everything els free as a bird and looks good but need to download the manual for clearances and new plate widths (unless any kindly soul daft enough to be reading my ramblings knows clearances for the 9 clutch packs?) to see what needs replaced, if you can get the box off the truck yourself you can def strip it down if yr clean and reasonably methodical, Just circlips hold friction plates in so from what can see so far only need spring compressors to change pistons, tomorrow’s mission is to find out how to test the pistons with air? remember to take the fill tube things out or big back drums won’t come out..... big epicyclic bar steward thing heavy so if u stick yr fingers in and tip box up like I did do it slowly! Tomorrow is another day!!!
 

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Wazzajnr said:
Manual was already in my Dropbox in the tech archive.
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Took me days to figure out how to post sumet man, can find me way round a toolbox but wouldn’t know what a Dropbox was if it fell on my head! Can’t even get imojis on me posts........?
 
Hybert said:
Currently deciding about buying a 04 TD6 with transmission issues, where it won't engange revers and is slipping. Would it be enough to change the vale block and clean out the oil cooler for the gearbox, or is the problem more complex?
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I guess all TD6 L322's are going to have gearbox issues at some point, as long as a recon gearbox and TC are reflected in the asking price (around £1500) then I wouldn't let it put you off.
At least you will know it's been done and you can save your money for all the other things that will break :)
 
Ratae said:
For parts could be worth giving these a call. Used them for bits for my ZF4HP22 last year. Quick mail order & take orders over the phone.
https://jpat.co.uk/index.html
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Cool cheers mate! Think I rang them about TC and they wanted £410+vat to refurb mine.............. if I can find the cash I’m just gonna replace everything while it’s in bits! But I’ve written down all clutch clearances so will check first and gonna see if I can leak test the pistons with weak soapy water and air first! No way these spots that remove box and refurb for £1300 are replacing parts that’s still in spec!!
 
backinblack said:
I guess all TD6 L322's are going to have gearbox issues at some point, as long as a recon gearbox and TC are reflected in the asking price (around £1500) then I wouldn't let it put you off.
At least you will know it's been done and you can save your money for all the other things that will break :)
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It’s a work in progress but one of my favourite quotes is by Mr Rolls or Royce can never remember which, “anything you can do, or believe you can, Begin it!!!” Owt this daft thing costs me now compared to fuel Ive put in 4.6L V8’s in last 4 years is just knuckles tools n time..... ran a mk2 hilux singlecab for 10 years and am where I am because I chose to be here!!!
 
My comments were more of a reply to Hybert and not to be too bothered about a dodgy GB & TC as long as it's reflected in the price.

I agree that if you have the time, space, knowledge and balls to tackle it yourself then I'm all for it, and I commend you for posting your finding on here to enlighten others.
I'm no mechanic but I have done a head gasket (300tdi), oil pump chain and sprocket (TD5) as well as the usual disco welding. For those not so confident at spannering it has to be factored in to the asking price.
 
backinblack said:
My comments were more of a reply to Hybert and not to be too bothered about a dodgy GB & TC as long as it's reflected in the price.

I agree that if you have the time, space, knowledge and balls to tackle it yourself then I'm all for it, and I commend you for posting your finding on here to enlighten others.
I'm no mechanic but I have done a head gasket (300tdi), oil pump chain and sprocket (TD5) as well as the usual disco welding. For those not so confident at spannering it has to be factored in to the asking price.
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Done that but not sure I'd be confident enough to pull that TD6 box apart.
 
Yup anyone can take things apart! Got the proper manual and all clearances wrote down just waiting for mag stand to arrive for DTI then can check everything and order parts and will see what happens when it’s back in.........:eek: any luck will be ok and hopefully give few more folk the confidence to tackle it themselves!!
 
Belser said:
Yup anyone can take things apart! Got the proper manual and all clearances wrote down just waiting for mag stand to arrive for DTI then can check everything and order parts and will see what happens when it’s back in.........:eek: any luck will be ok and hopefully give few more folk the confidence to tackle it themselves!!
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You may even have a rebuild side line considering the number of TD6 's with gearbox issues. ;):D
 
Wife been away so been holding fort and drinking loads of ale, got back to it last night and def found fault! Fwd and coast clutches fairly fried but could see straight away direct clutch (bottom of first big drum out) had about 5mm clearance and when took plates out they just metal but not welded together, have ordered valve block and full seal kit £109 on bay and full set of frictions £210, there’s a non exchange TC for £300 does anyone know if can get one cheaper on exc anywhere? Although if get that can cut mine open for a look inside!! All pistons seem ok and not leaking air past so taking a gamble and not doing them! Might regret it later on but fairly familiar with everything now so stripping it down again holds no fear and wid oil n filter job gonna stand me at £700! Was told off a couple of long standing companies the places that say £1300 suddenly find lots more wrong once they open box up and yr bill magically grows!! Spot in Newcastle been on go since 70’s £2200+vat so fair saving if it works! Only proper tool I’m going to buy if I can’t get dimensions and fabricate one is the H gauge for final clearance checks, can turn TC end seal tool and Teflon seal fitter/ resizer on lathe so ok for them! Will post findings when open valve block up as well aware I’ve found the fault but not the cause yet!! Only original fault codes were 5th gear ratio incorrect and transmission component slipping so fairly confident nothing electronic is goosed! Ever the optimist........ :cool:
 

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