Boxes OFF!!!

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tjwaines

Active Member
Posts
138
Lads and lasses, im gonna be removing mi 'boxes this coming weekend to have them re-conditioned. Gonna have a look for the relavent manuals etc but was also wondering if anyone had encountered any pits falls when doing theirs, tips pointers etc (tits also if possible)?

She's a 300TDi 90.
Also gonna be doing the clutch assembly and both cylinders at the same time.
Cheers
Tom
 
Dunno wot boxes you've got fitted, I did my gearbox, LT77, a couple of years ago an it int that difficult.

You'll have to make or buy some special tools to get it all apart, a bearing splitter and puller to get the collar off the output shaft, a locking tool to get the fifth gear nut off an a big fook off torque wrench to put a new un back on are the ones that spring to mind.

I'd take the synchro hubs apart and have a look at the slipper pads inside them, one had worn on mine making it get stuck in third gear, I had to strip the box a second time before I sussed wot it was.

I've only replaced the output housing bearings on the transfer box an that was pretty simple.

If you use the downloadable manual on here somewhere it's pretty good.
 
The tranny box and gearbox are coming off!!!
Its not an issue for the rebuilding, im sending them away to Ashcroft transmissions for that, as i would like it to stay in one piece after its been done!!! Just wondered about the removal and refitting, how difficult is it to re connect the linkages in correct positions???
cheers
 
Piece of ****. If you've lifted the suspension or have oversize wheels then it's even easier cos you don't have to raise the vehicle.

Take the seats an floors out, take the gearchange housing off, Make a rig to fit in the cab resting on the chassis an fit a chian hoist to it drop the whole lot onto a sheet of ply on the floor an pull it all out from underneath.

Stand the boxes up on the bell housing an undo the nuts an bolts connecting them, one bolt is longer than the other so make a note of wot hole it came out of cos if it goes back in the wrong un it'll lock yer transfer box up.
 
Cheers Grunt, I was only gonna bother with the centre hatch but I suppose it'll be far easier to get at everything with all seats out. Im gonna send it away as one lump, not gonna bother splitting em and get them to send it back as one lump save a bit of faffing around.

Bloat, it being a 300TDi that kinda denoats LT230 Tranny box and R380 gearbox doesn't it, correct me if im wrong, but didn't all 300TDi Defenders come outa the factory like that?

Also on refitting im putting an X-Eng handbrake conversion kit on, i know i need the earlier cable but would be much appreciative if someone could give me a link to the right one on Paddocks or similar.
Cheers
Tom
 
was only gonna bother with the centre hatch but I suppose it'll be far easier to get at everything with all seats out.
Click to expand...
Yer can do it leaving yer seats an stuff in but it dun't leave much room fer yer elbows an yer can have a good look at the chassis an stuff while you've got everything out.
 
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