TD5 Manual Transmission failure diagnosis - LT230?

Brown said:

I think so. If they're Dingocroft items they'll be nicely made. But two of the fixings are studs anyway so it's easy enough to get things lined up.
Oh, and one mistake I've made concerns the bolts holding the gearbox to the transfer box. They're slightly different lengths. For the hole that's between the main gearbox and the nose cone that contains the centre diff, you want to select the shortest one. I've put a longer one in by mistake, which fouls the centre gears of the transfer box and they won't go round at all. So hope that saves you a little time and frustration!

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Noted. Thanks.

The main thing is to have fun and post us some pictures.

Update. We got access to the lift and some time off yesterday, so started work. Turns out that getting a Defender with no drive (nasty noise and severe vibration only) over a curb, up a tarmac slope and onto a 4 post lift is more difficult than we anticipated. We got up the curb 45 degrees to the ramp by towing behind my D2, and then spent the morning getting it straight enough to go on the ramp by winching it forwards using a farm jack and letting it ease rearwards on full lock. I've never felt the need for an electric winch before, now I really want one.

Opened up the transfer box and found nothing abnormal whatsover. In fact it look pristine, the oil level was fine and the colour as good as it was when we changed it a year ago, there was no swarf on the drain plug. The edges of the cogs were immaculate with no signs of wear, the central diff rotated smoothly from either flange and it moved smoothly from hi to lo and CDL locked and unlocked normally.

Drained the oil from the main gear box and while the oil (Dexron III) was clear, red and sweet smelling, the drain plug looked like a hedgehog.
With the props disconnected we selected each gear in turn. The clutch felt normal weight and you can feel as it engages, there was no drive even on 5th. Right now I'm thinking main gearbox output shaft and looking at an Ashcroft rebuilt box with a longer 5th gear and fitting a LOF uprated clutch with solid mass flywheel while we have the opportunity.

However, before spending the cash I would really like to know for certain that we have identified the problem. Any thoughts?

The Car Club at Boscombe is not that well equipped: the roof is too low to allow the D90 to be raised higher than 3 feet (though in itself this is not a problem), the engine hoist is beam mounted and cannot be used inside the cab and there are no gearbox jacks. Swapping transfer boxes is one thing, but what we are now looking at is well outside our comfort zone, so have started looking at local specialists. Has anyone heard of or used FBB Land Rover down towards Salisbury, or have any recommendations?

Try ASV at Andover. He’s got a good reputation locally and is on Facebook.

https://www.asvrepairs.co.uk/#contact

Knappster said:

Try ASV at Andover. He’s got a good reputation locally and is on Facebook.
https://www.asvrepairs.co.uk/#contact

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Thanks will call them on Monday.