Thread: gearbox dead - 200tdi '93 110

Originally Posted by Top End Rangie

It appears that whole assembly is full off grease,is the assembly usually below oil level or not?

no i think it's all the metal filings mixed with oil from over the years.
it would not be under oil... as you see the oil level plug is far below the input gear.



must be why they make the cross drilled ones now eh?
mine was not cross drilled.

so... i will have to pull the whole gearbox out after all eh?
in this case, would you recommend a full overhaul kit to be put into it?
apparently 170,000 km's on the clock so far...

has anyone who is not a professional mechanic done a rebuild on an R380 like this before with success?
Lots of special tools required if I understand correctly.

I hate to be the one to break it to you, but yes, gearbox rebuild. I started to pull mine apart myself but gave up very quickly and took it to a mechanic I knew. Hopefully a mechanic will be able to advise on what needs replacing once it's apart. Hopefully your gears will all be ok, but you'll probably want some new syncro rings (for the lower gears at least), bearings, seals, etc.

It's quite amazing that yours has lasted 170 000km. Mine went at 40 000km, as most others did around that mark from what I believe. I'm now just over 180 000km with the drilled input gear and no problems.

bugger, thats not good.

I have just rebuilt the r380 in my 90 after I broke the layshaft. The last few pages in my 90 thread in my signature have a load of pictures.

I had none of the special tools. The worst job is removing the collar from the main shaft.

It is possible. Take a lot of pictures when you do it. You will most likely need to refer back to them

There is I think a mistake in the workshop manual too with reference to the syncro hub for 5th/reverse too, Make a note of the way it faces when you remove it.

Personally, I would try and find a good 2nd hand R380, then swap your bellhousing and other bits over to make it a "stumpy".

That will be easier than a rebuild.

The only problem is you are limited to defender R380s. Disco versions (usually cheaper) will bolt in but put the shifter where the cubby box is.

However that still gives you 1994-2007 gearboxes, however 1999-on boxes are stronger. You can even uy a complete box and t-case.

Some of the stumpy bits may not fit a later box, but Ashcroft transmissions can tell you what bits will fit and what won't, and sell you anything you need for a reasonable price. e.g. I bought all the bits needed to turn a disco box into a stumpy from them.

Thanks Psimpson7, I had a look through your thread.
very nice looking work.
it is encouraging to see someone without experience and the SPTools can have a crack at it.
Did you do much work with the Mainshaft or was the collar the only thing you needed to remove from it?

But I am afraid I will not even be able to do that much, I have no workshop, bench vice, bearing press, torque wrenches, dial indicator etc etc...

At best I can get the box out and take it to someone who will do the rebuild for me.

Maybe I can order a rebuild kit from Ashcrofts to be fitted, that would save me some good $ no doubt.

Originally Posted by gmeddy

Thanks Psimpson7, I had a look through your thread.
very nice looking work.
it is encouraging to see someone without experience and the SPTools can have a crack at it.
Did you do much work with the Mainshaft or was the collar the only thing you needed to remove from it?

But I am afraid I will not even be able to do that much, I have no workshop, bench vice, bearing press, torque wrenches, dial indicator etc etc...

At best I can get the box out and take it to someone who will do the rebuild for me.

Maybe I can order a rebuild kit from Ashcrofts to be fitted, that would save me some good $ no doubt.

Your chances of finding someone to (competently) rebuild an R380 for a reasonable price are probably pretty unlikely in Kunners - based on my experiences.

If I were you I would look for a good 2nd hand box, or just import one from Ashcroft.

It hasn't torn the centre out of the clutch plate has it ?.

my R380 in my 200tdi defender has done roughly 400 000km's(odo stuck on 300 009 for 6yrs) and the previous owner had no big work done.

Although mine has to have a rebuild because the synchros are non existent and bearing noises.

Beachboro 4x4 seam good and thats where im probably getting mine done but thats not much use in kunners i supose.