Corne215 · Feb 8, 2025

Hy guys
My gearbox packed up few months ago on my disco 300tdi.
Bought recon one guy i got it form said it came of a v8 landy but is a r380 53a gearbox he said it wil fit my 300tdi. Got gearbox home took my old gearbox bell housing off my gearbox and fitted to the new gearbox
Got new clutch fork and an the res fit it all back to the disco when she idles clutch in but can’t get gears.

My old gearbox was a r380 55a wil the 53a work on the 300tdi reason for me asking is I don’t think my clutch is working at all and this is the 3rd time i had to take out this gearbox alone so im desperate for any advice before i put this gearbox ont the engine.

Corne215 · Feb 8, 2025

Is normal for the pressure plate fins to be this flat after its been torqued 25Nm

Anaconda · Feb 8, 2025

Was the gearbox from a proper rebuilders and did you fit a new clutch kit?

discool · Feb 8, 2025

Corne215 said:
Hy guys
My gearbox packed up few months ago on my disco 300tdi.
Bought recon one guy i got it form said it came of a v8 landy but is a r380 53a gearbox he said it wil fit my 300tdi. Got gearbox home took my old gearbox bell housing off my gearbox and fitted to the new gearbox
Got new clutch fork and an the res fit it all back to the disco when she idles clutch in but can’t get gears.

My old gearbox was a r380 55a wil the 53a work on the 300tdi reason for me asking is I don’t think my clutch is working at all and this is the 3rd time i had to take out this gearbox alone so im desperate for any advice before i put this gearbox ont the engine.

Are you unable to select a gear/s without the engine running?

If yes then try starting engine in gear, brakes on of course, Ive had to do that with a summer car I have in the garage as the clutch plate have been known to be stuck over the winter, brutal but it frees the plate… the clutch is cable operated so don’t have any issues with hydraulic clutch operation

The only difference I know with the R380 is the fifth gear ratio, diesel 0.730:1 and petrol 0.791:1.
But then i’m not a gear box specialist

Kev12 · Feb 8, 2025

I thought the input shaft was different but I maybe confused with earlier ones. Is the clutch plate definately in the right way around?

Corne215 · Feb 10, 2025

Anaconda said:
Was the gearbox from a proper rebuilders and did you fit a new clutch kit?

yes gearbox is fine it selects all gears when the landy is of but when she idle clutch in not selecting gear new clutch was fitted

Stanleysteamer · Feb 10, 2025

Where is James Martin when you need him?
He'd know, so sorry he left.
The problem seems to be in the thrust-bearing, clutch lever, clutch fingers area.
As depressing the pedal isn't making the clutch disengage.
Is the fulcrum right? Is the thrust bearing right?
How much free play is there at the clutch lever? Could the cable be shortened a fraction even just temporarily to see if that helps.? By pulling it through the end of the lever and putting something over the end of it so it acts quicker on the lever?
Is there anyway of adjusting the cable at the pedal end?
Best of luck mate.
Coincidentally I have the same problem with a semi-auto Porsche speedster replica based on a Beetle chassis. the clutch plate had to be remanufactured and that was done twice when the company got the thickness wrong the first time. It is a pull clutch too which is rare on cars.
So totally sympathise with your problem.
It cost us £1500 at a garage to end up being forced to drive it home 5 miles in one gear.
Have yet to look at it.

PopPops · Feb 10, 2025

Stanleysteamer said:
Where is James Martin when you need him?

+1 ^
A huge mine of experience and knowledge….

Corne215 · Feb 10, 2025

Stanleysteamer said:
Where is James Martin when you need him?
He'd know, so sorry he left.
The problem seems to be in the thrust-bearing, clutch lever, clutch fingers area.
As depressing the pedal isn't making the clutch disengage.
Is the fulcrum right? Is the thrust bearing right?
How much free play is there at the clutch lever? Could the cable be shortened a fraction even just temporarily to see if that helps.? By pulling it through the end of the lever and putting something over the end of it so it acts quicker on the lever?
Is there anyway of adjusting the cable at the pedal end?
Best of luck mate.
Coincidentally I have the same problem with a semi-auto Porsche speedster replica based on a Beetle chassis. the clutch plate had to be remanufactured and that was done twice when the company got the thickness wrong the first time. It is a pull clutch too which is rare on cars.
So totally sympathise with your problem.
It cost us £1500 at a garage to end up being forced to drive it home 5 miles in one gear.
Have yet to look at it.

Thank you for the reply im going to fit it all back and see what happens
and will get back to you hopefully it works this time

Kev12 · Feb 10, 2025

Kev12 said:
Is the clutch plate definately in the right way around?

Stanleysteamer · Feb 10, 2025

Sorry, had to laugh as you posted this in post#5 and have had no answer.
TBH most of them have "fly wheel side" printed on them and I am not sure one fitted the wrong way round would even touch the flywheel properly, but then I have never done a clutch on a 300tdi.
It is of course a really good question and not patronising at all.

marjon · Feb 10, 2025

Kev12 said:
I thought the input shaft was different but I maybe confused with earlier ones. Is the clutch plate definately in the right way around?

I also thought there was a difference in the input shaft, as in the size of the pigot bush, (and length maybe?).

Suggest diamensions (and spline count?) are checked before the effort of putting box in.

J

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