Hi guys,
I know the spigot bearing on my Disco 2 has being needing attention for quite a while now (whining first thing on a morning when maneuvering slowly).
But gears have also been getting harder to engage lately (there was a big 'notch' going into 4th, not hard to engage, slipped in easy enough but just made a vibration unless revs were matched), and i was sitting at traffic lights the other day and there was a loud metallic chattering noise, I wouldn't say it was deafening, but it was scarily loud. I can't remember if i had the clutch engaged or not.

So I thought it was time I had a go at removing the gearbox and take a look at whats going on.

I don't think I've ever come across so many seized bolts, had to cut the crossmember bolts out.
But the gearbox assembly is out finally.

I was hoping for an obvious problem (clutch plate worn or something simple like that), but nothing really stood out.
I'm able to wiggle the main input shaft quite a lot (but i think this is quite normal?)
The clutch plate fingers seem really worn right to the centre, I thought it might be this making the noise, but then I also wouldn't have thought the thrust bearing would be able to make such a loud noise/vibration that i felt. And it wasn't a constant problem.

On draining the transmission oil, there were lots of grey fillings on the drain plug, not sure if this is just wear from the notchy 4th gear, or if something else is at play.

I'm not sure where to go from here really other than stripping the gearbox.

I also wanted to remove the flywheel (might as well replace it while ive got the gearbox off). But the bolts are stuck and rounding off. Is it ok to use a propane torch on these to heat them up?

Cheers,
Kane

you need a thin wall 13mm socket for clutch cover and a decent impact 15mm socket for fly wheel bolts they are very tight you might need to hit bolt heads very hard a few times with a large flat punch and decent sized hammer,pull input shaft in/out there should be no free play, clutch finger wear is normal , pull on flywheel it should rotate but not pull back much at all and shouldnt clang if rotated hard

Thanks! I was sceptical that the impact wrench would remove the flywheel bolts, but sure enough, got a decent halfords advanced impact socket and the bolts came straight out!!

The flywheel didn't pull back, but it rotated back and forth about 5-10 degrees freely (guesstimate) before feeling a pressure against it. I'm assuming this is normal from your description.

I'm not in any real rush so looks like its time to have a go at dismantling the gearbox.