New box, but sticky gears

flatlander · Dec 2, 2015

I've just had a refurbished LT77 Ashcroft gearbox fitted to my 90, together with a rebuilt tranny box. The garage fitted a spigot bush, but the clutch and slave cylinder were only about 4000 miles old, so these were untouched.
Reverse gear is now much harder to change out of, with a very firm pull needed. It is harder when the engine is running, as though the clutch is dragging, but free movement at the top of the clutch stroke is about 1/2 " as it was before, and the clutch bite point is the same as far as I can tell. I had the flywheel surfaced when I rebuilt the engine, and is is still smooth and unwarped.

The only thing I can think of is that the spigot bush is too tight a fit on the shaft, attempting to turn the shaft and applying pressure through the gears. Any other suggestions or comments welcomed.

nobber · Dec 2, 2015

flatlander said:
I've just had a refurbished LT77 Ashcroft gearbox fitted to my 90, together with a rebuilt tranny box. The garage fitted a spigot bush, but the clutch and slave cylinder were only about 4000 miles old, so these were untouched.
Reverse gear is now much harder to change out of, with a very firm pull needed. It is harder when the engine is running, as though the clutch is dragging, but free movement at the top of the clutch stroke is about 1/2 " as it was before, and the clutch bite point is the same as far as I can tell. I had the flywheel surfaced when I rebuilt the engine, and is is still smooth and unwarped.

The only thing I can think of is that the spigot bush is too tight a fit on the shaft, attempting to turn the shaft and applying pressure through the gears. Any other suggestions or comments welcomed.

Have you set up the selector properly?

flatlander · Dec 2, 2015

nobber said:
Have you set up the selector properly?

I bottled out of installing it myself, due to the gravel drive, cold weather and general idleness on my part. A good garage fitted them for me, and included a slick shift.So, I would expect them to have set it up properly All other gear changes seem OK, a little stiffer than before, but with the reduced leverage of the slick shift this might be expected..

tottot · Dec 2, 2015

It is just reverse you say, so unlikely to be clutch/shaft problems.Rebuilt units can be stiff for some time, mine was.

nobber · Dec 2, 2015

On the side of the turret, left side is an adjuster for reverse, its basically a spring.
I would get in touch with Ashcroft, they are very helpful, there is information on their web site about setting up one of their boxes.

jamesmartin · Dec 2, 2015

id say your clutch is dragging free play on the pedal isnt an indicator of clutch

jamesmartin · Dec 2, 2015

nobber said:
On the side of the turret, left side is an adjuster for reverse, its basically a spring.
I would get in touch with Ashcroft, they are very helpful, there is information on their web site about setting up one of their boxes.

the same as any body elses box

nobber · Dec 3, 2015

jamesmartin said:
the same as any body elses box

I like a nice tight box, cant do sticky sloppy boxes, it has to glide in, nice and slow , nice and tight, Precise but without any farting, 1 Oh , 2 Mmmm , 3 Ohhhhh , 4 Yes , yes , 5 Ah my god yes, R Aaaaaah mmmmm yeeeeeeees.
That's how I like my boxes.

jamesmartin · Dec 3, 2015

nobber said:
I like a nice tight box, cant do sticky sloppy boxes, it has to glide in, nice and slow , nice and tight, Precise but without any farting, 1 Oh , 2 Mmmm , 3 Ohhhhh , 4 Yes , yes , 5 Ah my god yes, R Aaaaaah mmmmm yeeeeeeees.
That's how I like my boxes.

perhaps too much concern for a healthy mind

nobber · Dec 3, 2015

What ya tryin ta say James? Im just explainin how I like my boxes ta be.

jamesmartin · Dec 3, 2015

exactly

flatlander · Dec 3, 2015

nobber said:
On the side of the turret, left side is an adjuster for reverse, its basically a spring.
I would get in touch with Ashcroft, they are very helpful, there is information on their web site about setting up one of their boxes.

Thanks Nobber, I'll give them a call.

I'll draw a discreet veil over your sexual fantasies

flatlander · Dec 3, 2015

jamesmartin said:
id say your clutch is dragging free play on the pedal isnt an indicator of clutch

That's what I thought James, but the clutch doesn't begin to engage until about half way out, as before. Clutch, slave cylinder and bearing are all nearly new, and I had the flywheel face skimmed when I rebuilt it.

Zed. · Dec 3, 2015

I rebuilt an LT77 for my 200tdi Disco, fitted a new clutch while at it thinking I was doing good.....

Bastarding thing was notchy into first & reverse for a bit (500 miles maybe?) but now is nice, unsure if it was the bearing preloads being tighter than the origonal (sloppy) factory settings or just the clutch dragging...
'tis possible that when re-fitting the box it was hanging on the clutch splines slightly while trying to align properly but that would be down to me

think it was a britpart clutch if this makes any difference?

Rich.

jamesmartin · Dec 3, 2015

Zed. said:
I rebuilt an LT77 for my 200tdi Disco, fitted a new clutch while at it thinking I was doing good.....

Bastarding thing was notchy into first & reverse for a bit (500 miles maybe?) but now is nice, unsure if it was the bearing preloads being tighter than the origonal (sloppy) factory settings or just the clutch dragging...
'tis possible that when re-fitting the box it was hanging on the clutch splines slightly while trying to align properly but that would be down to me think it was a britpart clutch if this makes any difference?

Rich.

lr did specify 0 to 2 thou free play we have allways found 0 to 2 thou preload is best ,increasing preload only wears bearings and increase total resistance to drive, but could make rev harder to engage,notchy is usually baulk rings running

jamesmartin · Dec 3, 2015

flatlander said:
That's what I thought James, but the clutch doesn't begin to engage until about half way out, as before. Clutch, slave cylinder and bearing are all nearly new, and I had the flywheel face skimmed when I rebuilt it.

if clutch doesnt begin to engage till half way up it is a sign of uneven springing in cover ie a worn cover because greater travel is required for a worn or poor cover compared to a good one, you can expect a recon box to feel tighter and notchy as baulk rings often need some miles to run in ,but rev on an lt77 has no baulk ring it has a sliding idler

boguing · Dec 3, 2015

It does have oil in it?

flatlander · Dec 4, 2015

boguing said:
It does have oil in it?

First question I asked!

agew · Dec 4, 2015

I had a 'factory' rebuilt LT77 box on a previous Defender (crumbling first gear or some such, can't remember now), but I was warned it would be stiff for a few hundred miles........ Ye Gods! Stiff! It was a major workout to get ready for each change and a good long breather afterwards - but, true to word after a few hundred miles (istr I picked it up and promptly drive it to Devon on hols) it just eased its way into nice smooth action and lasted for ever quite happily (well til I sold it anyway....). Hope yours is bedding in the same..... A

flatlander · Dec 4, 2015

agew said:
I had a 'factory' rebuilt LT77 box on a previous Defender (crumbling first gear or some such, can't remember now), but I was warned it would be stiff for a few hundred miles........ Ye Gods! Stiff! It was a major workout to get ready for each change and a good long breather afterwards - but, true to word after a few hundred miles (istr I picked it up and promptly drive it to Devon on hols) it just eased its way into nice smooth action and lasted for ever quite happily (well til I sold it anyway....). Hope yours is bedding in the same..... A

I think I have an excuse for a nice long drive this weekend

New box, but sticky gears

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