LT77 Output Shaft Wear Fix

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Fishbones78

Member
Posts
28
Location
Oxfordshire, UK
Hi
Recently rebuilt the front axle of my 300tdi (was originally 2.5td) to get rid of some drivetrain slack. The output shaft of the box is also a bit knackered. Im 18 so cant nearly afford a refurbed box. I heard that the wear problem was fixed on the later gearboxes and was wondering if anyone knew what serial suffix this was. That way I can buy a good used box with the better oil flow so I know it isnt worn.

Thanks
 
it wasnt the the gear box that had the solution it was fitting cross drilled input gears in the transfer box that fixed the spline wear for r380s around 96/7 iirc
 
jamesmartin said:
it wasnt the the gear box that had the solution it was fitting cross drilled input gears in the transfer box that fixed the spline wear for r380s around 96/7 iirc
Click to expand...
I know you can buy the cross drilled input gear now, but did LR ever decide to use the cross drilled input gear on the LT77 from factory? If so what year? From my understanding the TDI was the death of LT boxes, so i would presume no as the fix came during r380?

Thanks
 
Fishbones78 said:
I know you can buy the cross drilled input gear now, but did LR ever decide to use the cross drilled input gear on the LT77 from factory? If so what year :)

Thanks
Click to expand...
no but you can do,lr nether bothered to do anything about mainshaft spline wear for the lt77 only when it became a problem with the r380s ,first fix was for the mod using an oil catcher plate just behind pto cover on transfer box this wont fit in the t/bvox if an lt77 is used unless you cut the splines of or drill a hole for the splines in the thrower boss,the crossed drilled inputs were then fitted to all lt230s and can be retrofitted to all but the earlier t/boxes ,lt230 suffix a and b boxes use frc5428 input gear an it never came in a cross drilled version,so you can fit a cross drilled input gear in an lt230 if its suffix c and later,the fact its connected to an lt77 is irrelevant
 
jamesmartin said:
no but you can do,lr nether bothered to do anything about mainshaft spline wear for the lt77 only when it became a problem with the r380s ,first fix was for the mod using an oil catcher plate just behind pto cover on transfer box this wont fit in the t/bvox if an lt77 is used unless you cut the splines of or drill a hole for the splines in the thrower boss,the crossed drilled inputs were then fitted to all lt230s and can be retrofitted to all but the earlier t/boxes ,lt230 suffix a and b boxes use frc5428 input gear an it never came in a cross drilled version,so you can fit a cross drilled input gear in an lt230 if its suffix c and later,the fact its connected to an lt77 is irrelevant
Click to expand...

Okay, so LT77 I cant fit a catch plate without cutting, but I can put the crossdrilled gear in the transfer box if the suffix is c or above. So that leads me to think I would be better buying a post 97 r380, ill do all the reading to see if that will fit now I suppose!
Thanks for the help
 
Fishbones78 said:
Okay, so LT77 I cant fit a catch plate without cutting, but I can put the crossdrilled gear in the transfer box if the suffix is c or above. So that leads me to think I would be better buying a post 97 r380, ill do all the reading to see if that will fit now I suppose!
Thanks for the help
Click to expand...
any 300 tdi lt230 will fit the g/box, but they have direct cabled hand brakes 200 tdi and earlier have a remote cable and bracket though the bracket will swap over if you drill and tap two 8mm holes in output housing
 
As James says you can retro fit a crossdrilled gear if transferbox of later suffix.If this is worth doing depends on how worn the gearbox mainshaft is.
Last year we put a crossdrilled gear in a mates landy as his mainshaft was only worn a bit,the good thing is the splines in the replacement gear were longer than the original and engaged with an unworn section of the mainshaft. As the shaft/gear splines can now get lubricated this can only extend the life of the unit. This can be done without removal of transferbox.
On my own 90 the shaft was to far gone so a refurbished main box and crossdrilled gear were fitted.
 
Thanks both of you for thr replies. I will inspect my output shaft and input gear when im home tomorrow properly. My 90 has serious drivetrain slack and hoping the front axle build and rear flanges have helped. Havent tested properly to see the difference as im not insured yet but the output shaft be worn too. Will lookout for a good LT77 or an R380 swap.
 
I fitted an oil plate to my lt77 and lt230 just fine, I had to knock out the mushroom bit in the middle of the pto cover and fitnit backwards so it would all fit properly (clearance issues)

5 years later and all seems well, next time I do an oil change I will pull the gears and look.

Ashcrofts helped me out, I rang them up :)
 
flat said:
Needed a break from painting so fitted an oil feed plate to stop my unworn splines eating themselves. Had a new gearbox in 2003 and the splines are pretty good.


also dropped off both props and checked the UJ's, had a good poke about underneath checking bushes etc and made a start on fixing the leaking front diff pinion seal. The nut is FT.

Also think my clunking noise is from the front diff it has a lot more play than the rear and the rest is all fine, a frame is new and bushes are all good. hmmm...

Ed

p.s oh yeah took it on 2 x 60mile journeys and it was flawless apart from the clunk :)
Click to expand...

That’s the oil feed plate, I got it from ashcrofts
 
tottot said:
As James says you can retro fit a crossdrilled gear if transferbox of later suffix.If this is worth doing depends on how worn the gearbox mainshaft is.
Last year we put a crossdrilled gear in a mates landy as his mainshaft was only worn a bit,the good thing is the splines in the replacement gear were longer than the original and engaged with an unworn section of the mainshaft. As the shaft/gear splines can now get lubricated this can only extend the life of the unit. This can be done without removal of transferbox.
On my own 90 the shaft was to far gone so a refurbished main box and crossdrilled gear were fitted.
Click to expand...

How hard is it changing the mainshaft? Can you get away with just changing that bit or is it worth just getting a total rebuild?
 
tottot said:
If changing main shaft you might as well rebuild the box given the work involved.
Click to expand...

jamesmartin said:
you would be stripping the box totally to swap the shaft so may as well fit new bearings etc
Click to expand...

Exactly why I will just get a new box. I can imagine its a bit complicated in there! Thanks for the links flat, I have been away this week but return home today, so Ill inspect my lt230 for its suffix and go from there.
 
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