BennehBoy's D2 adventure

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The most awkward to get to bolt of the ones holding the tbox to the R380 is completely rounded. I've tried every which way I can think of to get the bugger out but no joy. There's hardly any room to try get any purchase on it & I don't have a working welder to allow me to try weld a fresh nut onto it which means I'm having to drop both boxes in one lump.

I'm doing this on the drive so to avoid crushing myself with it all I've ordered a gearbox trolley jack adapter - should turn up later this week and I can then drop both boxes out and tackle the offending bolt with a lot easier access.

Still none the wiser about which box is faulty, but I do know the tbox was also low on oil :( Kicking my lazy arse now...

Here's a photo showing just one of the leaks...

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I got the oil collar off, pilot bearing is fine...

Can't find any tooth damage or bearing damage, but... I can't find the ring for the thrust collar that sit inside the oil feed ring. Can't imaging how that would fail and get chewed up??
 
TBH I'm not sure they even having a locking ring on the TD5 boxes.. I don't see one in the Ashcroft rebuild kit. Scratching my head about where this debris has come from.
 
Yeah I'll pull it all apart tomorrow most likely. It's taken some hammer over the last 10years so hardly surprised it's failed, just glad I noticed it before it totally grenaded.
 
Stripped down the LT230, and everything other than the intermediate gear is in tip top shape, none of the gear fragments got into any of the bearings which is amazing tbh - good job this happened within a mile of home.

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Here are the fragments that I fished out

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I've got a used non CDL box coming soon, I'll swap the intermediate gear in from that.

As for what caused the failure... the stake nut for the intermediate shaft was loose, the stalking on it looked a bit crap tbh, so I reckon this has allowed the gears to be forced apart and ride up one another until they snapped.

I've got a 300m shaft coming from ashcroft's and instead of using a crush tube I'm going to use a TD5 spec spacer tube... I measured up the crush tube and I have a spacer the exact same length.
 
The casing is already sleeved so no worries there.

I was considering an ATB, but tbh all I ever think of is that my MOT tester would knacker it checking my brakes :D
 
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