steve_debbie
New Member
Manual Gearboxes
I've just fitted a rebuilt gearbox to my Discovery, the third and fourth shifts are not very good. Why? I am familiar with the much talked about mainshaft wear problem on my Defender/Discovery but I don"t know how bad mine is, or if I need to look at replacing my gearbox? The R380 gearbox in my 300 tdi DefenderDiscovery has recently started 'blocking' when I shift from 5th to 4th, to get 4th gear I have to nudge 3rd then it will drop into 4th no problem. Why? I have a Tdi 90 and it "clunks" when I take up drive. Why? I have a 300tdi Disco with a 5 speed manual (R380) gearbox and have lost all drive. Why? I have a 300tdi Disco with a 5 speed manual (R380) gearbox and have lost fifth and reverse gears. Why? I've just fitted a rebuilt gearbox to my defender, the third and fourth shifts are not very good. Why? My 200 tdi Discovery is very difficult to change gear from 1st to 2nd or 3rd to 2nd. Why? What oil should I use in my R380 gearbox? What oil should I use in my LT77 gearbox? My gearbox rattles on idle, in neutral, with the clutch up When driving my 200 Tdi DiscoveryRange Rover the gearstick has suddenly become very vague and is flapping side to side. Why?
Transfer Boxes
I have a P38 Range Rover and when I pull off with hard throttle I get a bang bang bang from the transfer case area I have a Range Rover 3.9 Classic and have lost all drive. I want to change the input gear on my LT230 for a later cross drilled type, can I do this in situ or do I have to take the transfer box out? I have just fitted a new cross drilled input gear to my LT230 and it whines, is this normal? The difflock on my LT230 does not engage even though the selector rod moves to the right position. Why? I have just fitted a rebuilt LT230 transfer box and it is locked solid, i.e. I cannot turn it, why? What oil should I use in my Borg Warner transfer box? The tyres on my Range Rover are scrubbing when parking, any idea why? I have just installed a reconditioned LT230 transfer box and cannot get the difflock adjustment set properly. I checked the difflock input shaft before installing the transfer box and it does rotate through all three positions. But when I try to set the adjustment on the pivot bolt it either stays in difflock or will not engage difflock. What should I do? I want to raise the gearing on my Series I,II,III. Overdrives are getting hard to come by and expensive, what alternatives are there?
Automatic Gearboxes
I can pull off in position 1 on the shifter and reverse is OK but in 'D' it will either not pull away or will pull off in 3rd gear My Autogearbox is now only able to select reverse. Why? I have just fitted a rebuilt ZF gearbox but the gear shifting speeds is nothing like it used to be. I have to rev the engine really hard to make it change up. Why? I have a 4sp ZF, the car has suddenly become very "sluggish" pulling away, but once the engine gets up to 2,000 RPM ish the car pulls okay. Why? What oil should I use in my Auto ZFHP22? I have just fitted a reconditioned ZF autobox. I have filled the box with the correct amount of oil but have no drive at all, forward or reverse. Why? When I start my Automatic Range Rover in the mornings it takes a while to engage drive, it hasn?t always done this. This has become worse in the cold weather. Why? When I start my Automatic Range Rover in the mornings it takes a while to engage drive, it has not always done this. This has become worse in the cold weather. Why? I have a 4sp ZF, when I select "D" the vehicle won't move, when I select "1" the vehicle moves off. I can then select "D" and continue to drive normally. If I stop I have to start in first again. Why? I have a 4 speed ZF Auto and it sticks in first gear in the morning or when cold and is reluctant to change up from 1st gear. Once the gearbox has warmed up it shifts normally. Why?
Differentials
What type of locker or truetrac do I need for my vehicle? What oil should I use in my Detroit Truetrac? What oil should I use in my Detroit Locker?
Freelander Parts
What oil should I use in my IRD unit? My Freelander transfer case (IRD unit) is getting noisy and I am told it needs replacing. Why would it have failed so soon?
Miscellaneous
How do I contact you?
Manual Gearboxes
I've just fitted a rebuilt gearbox to my Discovery, the third and fourth shifts are not very good. Why? When you let go of the gearstick on either the LT77 or the R 380 Discovery boxes the stick will spring to the 3 / 4th gate. This gate position is set by the position of the plate shown here. This gate position must be adjusted correctly to agree with the selectors in the gearbox to ensure a good gearshift. When we rebuild the boxes we set this position but sometimes it needs fine tuning when in the car.
If the shifts to 3rd and 4th are not clean you may want to adjust this plate, to do this first you must drive the vehicle but when shifting into 3 and 4 instead of letting the gearstick go where it wants to go try holding it a little to the left then a little to the right, one way or the other it will drop in nicer. When you have worked this out you can slacken the 4 screws holding the plate and move the plate left or right accordingly to improve the shifts.
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I am familiar with the much talked about mainshaft wear problem on my Defender/Discovery but I don"t know how bad mine is, or if I need to look at replacing my gearbox? The best way of ascertaining the degree of wear is to chock the two front wheels, handbrake off, mainbox in first and jack up a rear wheel. Remove the PTO cover to the left of the handbrake and you will be able to see the gearbox mainshaft in the centre and the transfer case input gear around it. By rocking the handbrake drum you will be able to rock the gear around the shaft thus getting some idea of wear / backlash between the two.
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The R380 gearbox in my 300 tdi DefenderDiscovery has recently started 'blocking' when I shift from 5th to 4th, to get 4th gear I have to nudge 3rd then it will drop into 4th no problem. Why? A common fault on the early R380 gearboxes was the 4th gear baulk ring. The slot locating the synchro slipper wears and allows the baulk ring to rotate too far. This blocks the synchro assembly. It will be necessary to rebuild the gearbox, and replacing the baulk ring with a later type will eliminate this fault.
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I have a Tdi 90 and it "clunks" when I take up drive. Why? The most common cause is worn mainshaft spline but other things to check the A frame ball joint and the halfshaft drive flanges, especially if you have a 300 tdi Defender. To check mainshaft spline wear remove the PTO cover and with the main box in first gear rock the car backwards and forwards whilst looking into the end of the input gear. If the spline is worn you will see movement of the shaft in relation to the gear. Replace the gearbox and transfer box input gear (use a cross drilled gear to prevent recurrence of the problem).
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I have a 300tdi Disco with a 5 speed manual (R380) gearbox and have lost all drive. Why? There are three possible problems. 1) The mainshaft spline has worn away and is not engaging in the transfer case input gear, (most common) 2) the centre has torn out the clutch friction plate or 3) the mainshaft has sheared just inside the rear of the gearbox. 1) and 3) will require a rebuilt unit.
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I have a 300tdi Disco with a 5 speed manual (R380) gearbox and have lost fifth and reverse gears. Why? The layshaft extension has sheared off effectively disconnecting these two gears. You require a rebuilt or new gearbox.
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I've just fitted a rebuilt gearbox to my defender, the third and fourth shifts are not very good. Why? Most rebuilt gearboxes, including ours, come without the "turret". This the part that the gearstick bolts to. If you pull back the rubber boot on the turret you will reveal two large springs and two adjuster screws and locknuts. The role of these springs and screws is to set the rest position of the gearstick when you let go of it and is referred to as the 3/4 bias setting. When you fit a new gearbox this can sometimes need adjusting to agree with the selector shafts to ensure a clean gearshift. Firstly you need to work out which way to adjust it, to do this drive the vehicle but when shifting into 3 and 4 in stead of letting the gearstick go where it wants to go try holding it a little to the left then a little to the right, one way or the other it will drop in nicer. When you have worked this out you can adjust the screws the springs are resting on to lean the stick left or right until it shifts better.
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My 200 tdi Discovery is very difficult to change gear from 1st to 2nd or 3rd to 2nd. Why? A common fault with these boxes is a thrust washer in the 1 - 2 synchro assembly splitting in half and blocking movement. Rebuild the gearbox and replace both thrust washers in the 1 - 2 assembly.
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What oil should I use in my R380 gearbox? We recommend MTF94 in your R380 box.
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What oil should I use in my LT77 gearbox? We recommend ATF Dextron 2 or 3.
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My gearbox rattles on idle, in neutral, with the clutch up This is very common on both the 200 and the 300 TDi engined vehicles. The clutch friction plate has a ring of springs, which are there to soften the knock of the diesel engine to stop it being transmitted to the driveline. Often especially with a new clutch these springs are quite tight and a lot of the engine knock goes through to the gearbox and makes the gears "chatter" together when the box is in neutral and the clutch up, it goes when the clutch is depressed. This can sound quite bad and does vary from car to car but is not detrimental to the life of the gearbox and we view it as an undesirable characteristic of the LT 77 and R 380 as opposed to a fault with either the gearbox or the clutch.
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When driving my 200 Tdi DiscoveryRange Rover the gearstick has suddenly become very vague and is flapping side to side. Why? Inside the aluminium top cover of the gearbox, which is secured by two large Phillips head screws, you will find two large springs which rest on a L shape steel plate which give your 3th bias gate position. This L shaped plate is very prone to cracking off where it is bent which will result in you losing the 3th rest position when in neutral and thus the shifts will become vague. This plate is inexpensive and can be changed with gearbox in situ.The part number of this Bias plate is FRC9340.
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thank you debbie
