Greetings,

I've got a new (old) gearbox and transfer box on the way for my 2.5NA truck (LT77+LT230 obviously), The gearbox and transfer box are both from Defenders with 200TDI engines, with slightly less miles than 118k which mine has. Once I've put 'em in, I'm going to do a refurb on the existing box which might take me months, not only to do it, but to afford it. When I change over, I'm planning on doing the clutch, and was wondering if there were any other jobs which should be done whilst I've got the gearbox out etc? I can see it costing me an awful lot of money, but it'll future proof the truck a bit I'll be putting the other gearbox box back in at some point, so I can do some of the jobs now, and some again later in a 3 months time or whatever.

List of things I have so far

diff light switch which doesn't work at the moment
clutch, fork and thrust bearing
rear output oil seal on engine

Cheers.

Reinforce the clutch fork as I think they are prone to wearing through where the actuating rod presses on the fork.
There are several threads on this forum regarding this mod.

If you have one (I know the TD5s do) change the bronze flywheel spigot as they do wear and are a few quid on eBay. Getting the old one out of the end of the crankshaft can be fun though. Put a slight chamfer on the internal bore and the gearbox input shaft will slide in a lot easier if your clutch alignment is slightly out.

tombardier said:

Greetings,

I've got a new (old) gearbox and transfer box on the way for my 2.5NA truck (LT77+LT230 obviously), The gearbox and transfer box are both from Defenders with 200TDI engines, with slightly less miles than 118k which mine has. Once I've put 'em in, I'm going to do a refurb on the existing box which might take me months, not only to do it, but to afford it. When I change over, I'm planning on doing the clutch, and was wondering if there were any other jobs which should be done whilst I've got the gearbox out etc? I can see it costing me an awful lot of money, but it'll future proof the truck a bit I'll be putting the other gearbox box back in at some point, so I can do some of the jobs now, and some again later in a 3 months time or whatever.

Click to expand...

Are you going to take pictures as you do the swap? Sort of along the lines of the cracking stuff Busterbus does?

BTW...why are you putting the old one back in? Seems like a lot of work doing the box twice...

the camera on my phone isn't that good, and this is going to cost me an awful lot of money to do this job anyway, so I'm not buying a new camera on top of that I'll be working to guides that other people have provided too, and there are a few photo guides that are pretty much identical, blow for blow, so I don't think I need to reproduce the same thing again, especially given that I'm not able to be authoritative enough on the subject to be trusted! It's all going to be a learning experience for me..