08mckerp · Feb 20, 2011

Hi, currently planning on putting an r380 and 300tdi into my def 90. took the gearbox out of the disco today and thers a fair amount of sideways play on the main input shaft that goes from the engine into the gearbox. guessing this means the bearings shagged. Is this an easy thing to replace? also ino that my gearsticks are going to be coming up thru the seatbox. how easy is it to fit the defender selectors. ino it envolves a bit of work inside the gearbox but how dificult is it? am i going to need any specialist tools or a press to do either the bearing or sort the selectors out? Cheers Pete

Beast o Bodmin · Feb 20, 2011

make sure you hold the shaft by the seal .they do move about a bit when sat on the floor not conected to the clutch.

jamesmartin · Feb 20, 2011

side ways movement is not applicable try and check endfloat on input cp shaft .to change selector shaft you would need to pull seal collar of the mainshaft that would be the hardest part ,then remove extension housing ,undo 30mm spanner size hut on layshaft this pulls of rear brg at same time ,remove gear,remove 5th gear collets remove rear brg with brass punch ,remove 5th gear and circlip and synchro hub while ensuring out sleeve doesnt come off,remove rev gears ,undo 2 x bolt on top of case and remove interlock ,case will pull off ,remove layshaft and mainshaft with selector shaft ,refit with gear box brg plate supported and fit mainshaft and selector shaft vertically

Beast o Bodmin · Feb 20, 2011

jamesmartin said:
side ways movement is not applicable try and check endfloat on input cp shaft .to change selector shaft you would need to pull seal collar of the mainshaft that would be the hardest part ,then remove extension housing ,undo 30mm spanner size hut on layshaft this pulls of rear brg at same time ,remove gear,remove 5th gear collets remove rear brg with brass punch ,remove 5th gear and circlip and synchro hub while ensuring out sleeve doesnt come off,remove rev gears ,undo 2 x bolt on top of case and remove interlock ,case will pull off ,remove layshaft and mainshaft with selector shaft ,refit with gear box brg plate supported and fit mainshaft and selector shaft vertically

thats a bit extreme.

i would try it first.there not the most refined boxes in the world.

08mckerp · Feb 20, 2011

jamesmartin said:
side ways movement is not applicable try and check endfloat on input cp shaft .to change selector shaft you would need to pull seal collar of the mainshaft that would be the hardest part ,then remove extension housing ,undo 30mm spanner size hut on layshaft this pulls of rear brg at same time ,remove gear,remove 5th gear collets remove rear brg with brass punch ,remove 5th gear and circlip and synchro hub while ensuring out sleeve doesnt come off,remove rev gears ,undo 2 x bolt on top of case and remove interlock ,case will pull off ,remove layshaft and mainshaft with selector shaft ,refit with gear box brg plate supported and fit mainshaft and selector shaft vertically

Might leave the selectors then

though id quite like to have a go

What and where is the endfloat and cp shaft? Cheers

jamesmartin · Feb 20, 2011

the shaft that fits through clutch is input shaft and constant pinion shaft you check to see if it has end float in direction of shaft it will move side ways as is long and supported by taper brg and clutch spigot when connected to engine

08mckerp · Feb 20, 2011

ok, so how much play roughly is acceptable?? atm its only about 5mm in any direction? but thats a pretty rough guess from memory.

jamesmartin · Feb 21, 2011

its not side to side but end float thats important ,with brgs that are run in there should be no end float,

08mckerp · Feb 21, 2011

ok cheers. will have a look this evening. Cheers for all the help!

tottot · Feb 21, 2011

Disco gearbox in defender ok if you do not want to use center seat,high/low stick comes up where defender main stick was and main stick comes up on front edge of seatbox.A bit of feteling needed to make a tidy job but still enough room for cubby box behind.Drove a mates with this set up and found gear changing position better than standard.

08mckerp · Feb 22, 2011

tottot said:
Disco gearbox in defender ok if you do not want to use center seat,high/low stick comes up where defender main stick was and main stick comes up on front edge of seatbox.A bit of feteling needed to make a tidy job but still enough room for cubby box behind.Drove a mates with this set up and found gear changing position better than standard.

Any chance you can get some pics of it mate? cheers Pete

tottot · Feb 22, 2011

08mckerp said:
Any chance you can get some pics of it mate? cheers Pete

Sorry no pics , perhaps someone else has done it this way and can help?

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