Project Rusty.

dieseldog69 · Jan 20, 2020

Hicap phill said:
Tried to take 1 transfer box off only to find someone had welded the gear on due to splines not been there

OMG

I might bodge a little just to get me by but that is mental lol

No clunk thankfully, for sure I will need to get it sorted soon as no doubt I will forget to top it up, head off on a long trip and KaBooom as it grenades across the underside of the truck lol

Zed. · Jan 21, 2020

Hicap phill said:
Tried to take 1 transfer box off only to find someone had welded the gear on due to splines not been there

not uncommon, sometimes lasts a few years.........

Rich.

dieseldog69 · Jan 25, 2020

Oeph!!!

Not a happy bunny!

Tranny fluid snot meant to look like that

dieseldog69 · Jan 25, 2020

Pics to follow in a bit........

dieseldog69 · Jan 25, 2020

Off out for a test drive and dinner collection.

Will update when home but oh my

dieseldog69 · Jan 26, 2020

Had a bit of vibration and knew there was a little bit of play in the slider splines of the front prop, thought I would swap that out and change the transmission fluid while I was in there.

The transmission fluid was rancid and an emulsified mess, think I figured out what happened and it's my own fault it seems, the extended breather pipe that runs up the snorkel had slipped in the ties and was resting in the gutter and with all that rain we've had, it's found its way into the gearbox FFS.

Oh well.

This was the filter strainer as it came out.

This was the garbage on it, not metalic,some sort of varnish or paint flakes?

I filled the gearbox up with 1 litre of fluid and popped the transfer box in neutral and put the gearbox in 4th gear and let it run for a few minutes and drained it out, it was rancid still and looked like this.

Still rank but at least it's purple and not grey lol

Got a 400 mile round trip out tomorrow so it will get a good run and then when I get back tomorrow night I will drain it all out again and fill it up with more fresh ATF.

Yay, more work........

Looks like the good spare transmission I have will need the seals and bearings fitted up sooner rather than later and fitted PDQ!!!

jamesmartin · Jan 26, 2020

dieseldog69 said:
Had a bit of vibration and knew there was a little bit of play in the slider splines of the front prop, thought I would swap that out and change the transmission fluid while I was in there.

View attachment 198919

View attachment 198920

View attachment 198921

View attachment 198922

The transmission fluid was rancid and an emulsified mess, think I figured out what happened and it's my own fault it seems, the extended breather pipe that runs up the snorkel had slipped in the ties and was resting in the gutter and with all that rain we've had, it's found its way into the gearbox FFS.

Oh well.

View attachment 198926

This was the filter strainer as it came out.

View attachment 198927

This was the garbage on it, not metalic,some sort of varnish or paint flakes?

View attachment 198928

I filled the gearbox up with 1 litre of fluid and popped the transfer box in neutral and put the gearbox in 4th gear and let it run for a few minutes and drained it out, it was rancid still and looked like this.

View attachment 198929

Still rank but at least it's purple and not grey lol

Got a 400 mile round trip out tomorrow so it will get a good run and then when I get back tomorrow night I will drain it all out again and fill it up with more fresh ATF.

Yay, more work........

Looks like the good spare transmission I have will need the seals and bearings fitted up sooner rather than later and fitted PDQ!!!

props wrong way round ,not that it matters but for continuity,box is painted inside it flakes off especially when you strip them and steam clean the housing

The Mad Hat Man · Jan 26, 2020

I fort so.
Crikey!

dieseldog69 · Jan 26, 2020

Well the vibration is still there but much reduced

Gearbox was much better and didn't go quite as stiff when warm as last weekend but it was still awful when hot

The Mad Hat Man · Jan 26, 2020

dieseldog69 said:
Well the vibration is still there but much reduced

Gearbox was much better and didn't go quite as stiff when warm as last weekend but it was still awful when hot

At least the water is evaporating off

dieseldog69 · Jan 26, 2020

The Mad Hat Man said:
At least the water is evaporating off

It was terrible shifting once warm and it took some real force to get the gear lever across the gate to engage different gears, felt like there was no synchro at all on 3rd and 4th where previously they were the good ones

And I have water ingress into my foot well from puddles???........

Oh FFS

The Mad Hat Man · Jan 26, 2020

Good innit?

Henry_b · Jan 26, 2020

The LT77 in my old RRC was the worst change i think i've ever experienced.
Double clutching i found made life easier.

the main reason i got rid of it..

dieseldog69 · Jan 26, 2020

The Mad Hat Man said:
Good innit?

Pretty existing design feature I think?

dieseldog69 · Jan 26, 2020

Henry_b said:
The LT77 in my old RRC was the worst change i think i've ever experienced.
Double clutching i found made life easier.

the main reason i got rid of it..

I was doing the double clutching between 1st an 2nd but it was getting beyond a joke.

New gearbox will fix it and then it will be fine..........

Henry_b · Jan 26, 2020

dieseldog69 said:
I was doing the double clutching between 1st an 2nd but it was getting beyond a joke.

New gearbox will fix it and then it will be fine..........

I was floating gears after a while

Not ideal

dieseldog69 · Jan 26, 2020

Henry_b said:
I was floating gears after a while
Not ideal

I fancied an auto TBH but finding one the one for a 200Tdi is like hunting down hens teeth and after seeing how much it would cost me to get one of them there electronic controlled jobbers working in there is beyond my means in these present times.

I had looked at it as an opportunity to maybe replace the LT77 with a ZF GS6-37DS 6 speed manual but again, it's cost prohibitive with the need to get adaptors engineered etc.

jamesmartin · Jan 26, 2020

dieseldog69 said:
I fancied an auto TBH but finding one the one for a 200Tdi is like hunting down hens teeth and after seeing how much it would cost me to get one of them there electronic controlled jobbers working in there is beyond my means in these present times.

I had looked at it as an opportunity to maybe replace the LT77 with a ZF GS6-37DS 6 speed manual but again, it's cost prohibitive with the need to get adaptors engineered etc.

300 auto should be easier to find

Henry_b · Jan 26, 2020

I found continental drift was faster than a 300 auto at full chat

A nice TD5 Auto

jamesmartin · Jan 26, 2020

Henry_b said:
I found continental drift was faster than a 300 auto at full chat
A nice TD5 Auto

well yes but no different than a 200

Project Rusty.

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Think outside, no box required.

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Think outside, no box required.

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