TD5 2003 Disco - Gearbox issue

MikeDISCO · Mar 13, 2014

Hi Gents,

Having a few issues with my gearbox.

Started around 6 months ago with a slight crunch into 1st gear.

I managed it ok with selecting the revs and gently changin gear and it helped.

Now I have the same crunch when coming down the gears from 4th into 3rd and the original issue of selecting 1st.

What ever I have tried at loads of speeds and revs its always the same issue.

So im after a plan of attack really and obviously work on the cheapest things first.

Im thinking...

1, Change the gearbox oil (This has been done 10 months ago)
2, ............

Not sure what to try next? Any help or advice is appreciated.

Cheers

jamesmartin · Mar 13, 2014

if oil change makes no difference and reverse selects well you need new baulk rings ftc3584

MikeDISCO · Mar 13, 2014

ok thanks James, any decent links for a how to guide?

jamesmartin · Mar 13, 2014

it involves a complete box strip down

MikeDISCO · Mar 13, 2014

is this too much of a job for a DIY job?

ive done gear box and clutch and HG change on a 300tdi in the past.

or is this job another level?

jamesmartin · Mar 13, 2014

hard for me to say really ,youd need some pullers and press and 1/2"air gun

MikeDISCO · Mar 13, 2014

is there any info on the net on how to do it or photos etc?

jamesmartin · Mar 13, 2014

i think so some where , you could allways phone me

thought it was mine! · Mar 13, 2014

mike phone james best thing you could do. A true gent with a true knowledge on gearboxes, if he can't answer the problem there is no answer!

sierrafery · Mar 14, 2014

out of curiosity, what oil did you use in it?

Maaarrghk · Mar 14, 2014

Thinking of the simple things first, might it be a good idea to have a shot at bleeding the clutch first, before diving into the gearbox?

Just a thought.

JordanTD5 · Mar 15, 2014

The gearbox in our TD5 Disco developed the occasional crunch into third a while ago, but i was waiting until it got worse before diving in.

A few weeks ago the clutch went totally as the plastic backing cage on the release bearing failed and it would no longer push the fingers on the friction plate.

Since changing the release bearing (along with new clutch while it was apart) the crunching has totally disappeared. I'm assuming the crunch was caused by the bearing failing fully release the clutch as it got closer to failure.

Maybe worth a check if you can get a borescope into the bellhousing.

TD5 2003 Disco - Gearbox issue

MikeDISCO

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jamesmartin

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MikeDISCO

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jamesmartin

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MikeDISCO

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jamesmartin

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MikeDISCO

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jamesmartin

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thought it was mine!

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sierrafery

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Maaarrghk

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JordanTD5

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