jamesmartin said:
i doubt youll get it completely leak free, if it drips its worth fitting a seal
Click to expand...

I agree that getting it completely leak free is a HUGE ask, but it’s not impossible. It does drip, and has left a small patch where it’s sat since the box went belly up. It hasn’t ran since Monday 5th, but still drips. That was part of the reason for wanting to do the seals.
 
mick 1986 said:
The one I have just got has a small “bead” around the centre and a few other places, but I was advised to “put a small bead” around it to make sure it seals. I don’t want to be doing it again. He said the crank seal is a pig, but it has the plastic fitting cup, so can’t be that hard....can it?
Click to expand...
It is not getting the seal on to the crank with the guide that's the problem. The last one I had did not want to go into the flywheel housing. Others I have done have fitted fine. Just a hint/warning.:)
 
tottot said:
It is not getting the seal on to the crank with the guide that's the problem. The last one I had did not want to go into the flywheel housing. Others I have done have fitted fine. Just a hint/warning.:)
Click to expand...

Much appreciated. Hopefully it won’t be a bugger, but I know how jobs like this can be. Maybe I should have bought 2 seals...?
 
Well it’s all back together. The gearbox doesn’t leak at all, it’s been sat waiting with oil in for 2 days and is completely dry, the same can’t be said for the transfer box. I need to have a look at the lower cover plate, but that’s a job for another week.

It’s a bit difficult getting into 1st, 2nd, and 3rd, but I have only tried it while stationary in the shed. There doesn’t appear to be any noises that signal a problem, from what I can hear over the engine. I have just pulled out of the shed, but I’m blocked in by the digger, so have to wait for that to be moved (I don’t have a key). Hopefully it all goes well and changes much easier when it’s moving. To say I’m a bit nervous is a HUGE understatement.
 
When I changed mine it took a good number of miles for the change to become free [ recon I was used to the sloppy old one as well ] changed the oil at 500mls. Good luck.
 
tottot said:
When I changed mine it took a good number of miles for the change to become free [ recon I was used to the sloppy old one as well ] changed the oil at 500mls. Good luck.
Click to expand...

I have planned on trying to do 500miles this week, but not sure that’s going to happen. I will change the oil next week as that was also my plan. Thanks for the heads up though.

It drove home relatively well to be fair. There was a knocking noise coming from the box at initial startup, went when the clutch was dipped and didn’t come back. I have no idea what it was or what it could have been, but it’s made me really nervous about driving it. Gear changes are much better on the move, but not perfect. I’m guessing they will ease with time. No oil leaks from the box. It was stone cold to touch. Used all 5 gears, so time will tell. I will update after the first oil change.

Thanks to those who offered help and advise.
 
I have just returned from its first proper run out after the gearbox rebuild. For the most part it was ok. Gear changes are smooth, and not sloppy like with the old synchros. There is a small random knock that sounds, and feels, like it’s coming from the gearbox, it’s enough that my wife noticed it sat in the passenger seat. It seemed to only do it when pulling away, so may not be the gearbox, it could be a bush or something I haven’t tightened fully. I need to get it back in the shed and have another look. The gearbox has what I can only describe as “chatter”. It’s only when the clutch is released, and only when it’s in gear. I have no idea where it’s coming from or what it could be. Starting to think I should have scrapped this box and replaced it.
 
mick 1986 said:
I have just returned from its first proper run out after the gearbox rebuild. For the most part it was ok. Gear changes are smooth, and not sloppy like with the old synchros. There is a small random knock that sounds, and feels, like it’s coming from the gearbox, it’s enough that my wife noticed it sat in the passenger seat. It seemed to only do it when pulling away, so may not be the gearbox, it could be a bush or something I haven’t tightened fully. I need to get it back in the shed and have another look. The gearbox has what I can only describe as “chatter”. It’s only when the clutch is released, and only when it’s in gear. I have no idea where it’s coming from or what it could be. Starting to think I should have scrapped this box and replaced it.
Click to expand...
chatter can be normal with a new clutch fitted especially if heavy duty, did you use the 2 shortest bolts that secure t/box to g/box on rhs that go front to back
 
jamesmartin said:
chatter can be normal with a new clutch fitted especially if heavy duty, did you use the 2 shortest bolts that secure t/box to g/box on rhs that go front to back
Click to expand...

Yeah I’m quite sure I used the short bolts on the two through holes. I’m almost certain I did as I could turn the gearbox input shaft by hand and the transfer box output flanges both turned. I’m guessing if the wrong bolts were used, one of them would have bound up and stopped me turning it by hand?

The more I think about it, the more I think the bang was something not really related to the gearbox internals. I could be kidding myself though.....?

Edit: it is a heavy duty clutch, but it’s not new. I would guess it’s got 30-40K miles on it, but you could clearly see the matching marks on it still.
 
I have this oil in the gearbox at the minute, but the more I think about it, the less I think it’s the right one. Any advice?

upload_2020-10-28_14-9-55.jpeg
 
I have been out and checked the oil level. A dribble came out of the fill plug, so I can only assume it’s at the fill line (I did put 2.5l of oil in it when it was rebuilt). I emptied the boot of all the ****e I had used to do the gearbox, then went out for a run again. The bang that can be heard is definitely coming from the back end, possibly axle or bush related so for now that can be ignored. The gearbox “chatter” is worst in 3rd, it tends to fade away to an almost stop under throttle, but as soon as the throttle is backed off its back again. Short of removing the box and stripping it, I’m thinking of changing the oil and testing it again, but I don’t know what else to do?
 
@jamesmartin @tottot have either of you fitted the Ashcrofts oil pump to the LT77? I’m wondering if that’s what is chattering inside my gearbox? It makes sense when I think about it, sort of.

The main reasons for thinking it’s the pump are, it’s steel and not composite. The drive gear (pump) didn’t have the “dome” on the rear. The gears weren’t the exact same size and profile as original ones. I’m just thinking it could be “rattling” inside the oil pump housing and causing it.
 
mick 1986 said:
@jamesmartin @tottot have either of you fitted the Ashcrofts oil pump to the LT77? I’m wondering if that’s what is chattering inside my gearbox? It makes sense when I think about it, sort of.

The main reasons for thinking it’s the pump are, it’s steel and not composite. The drive gear (pump) didn’t have the “dome” on the rear. The gears weren’t the exact same size and profile as original ones. I’m just thinking it could be “rattling” inside the oil pump housing and causing it.
Click to expand...
no i never fitted one, fibre pump isnt normally a weak part as such
 
You must log in or register to reply here.

Similar threads

Skolmate
Defender 200tdi LT77 noise and rebuild
Replies
13
Views
859
dag019
dag019
dag019
A question of gearboxes
Replies
16
Views
930
Skolmate
Skolmate
Frisol
Series 2a Gearbox - retaining compound, grease, and oil seal "compound"
Replies
5
Views
1K
Wildefalcon
W
Kiwi Landie
Series 3 Rebuild Series 3 Suffix B gearbox as Suffix D
Replies
12
Views
1K
BikerB
BikerB
UpandOver
Adwest 4 bolt steering box input shaft seal - help!
Replies
1
Views
1K
tottot
tottot