Thread: gearbox dead - 200tdi '93 110

50_dent is in Darwin, and a mechanic! may be worth a PM at least

I've sorted out parts from Ashcrofts mainly, had to get the R380 rebuild kit from elsewhere in the UK as Ashy was out of stock.

Getting the parts shipped direct to MR Automotive in Redcliffe and I will remove the GB tomorrow afternoon and take it up to Katherine (500km each way) to be put on a truck over to QLD for MR's to do the job.

It's a lot of stuffing around, but the small price we pay for living outside of the 'Rat-Race'.

Decided that I may as well order the rebuild kit for the LT230 at the same time and also do a ratio change to 1.222 because we do a bit of highway driving.
May as well get it all done now while I'm doing it, otherwise we might get caught out somewhere down the line.

will keep yas posted.

got the box out on saturday arvo,
found lots of black engine oil in the bell housing... new rear engine oil seal needed i guess.

clutch thrust bearing is stuffed, new clutch time as well.

at least the input shaft is looking good.

any opinions on the clutch? I'm looking at Exedy HD pink clutch - good?

I bet there's a thread somewhere about clutches...

where the heck did the link to "channels" go? that used to take me where i wanted to go!

it took a week of stuffing around before i could send them over east, and a week of them sitting at the shipping yard in Bris before they were sent back, but yesterday they finally arrived!


gleaming with good-as-new beauty!



my new mod - the expanded transfer case oil sump, for 500ml extra oil and cooling fins!

a day and a half of hard work later and i'm driving around enjoying the higher ratio gears I also had MR Automotive fit to the Transfer case, I now have the same gearing as the Disco's and it's VERY easy to notice the difference!

so happy right now!

if your interested in the expenses:

to have the new input gear and bearings for the transfer case, as well as a full rebuild kit... and the special sump, and the ratio upgrade, and heavy duty cross pin Ashcroft Transmissions - HD Cross Pin

new mainshaft, fifth/reverse synchro hub and full rebuild kit for the R380...

All parts (apart from the synchro hub which I didn't know I needed) ordered from Ashcrofts in UK and sent direct to MR Automotive in Queensland...

$1455 in parts from UK
$1870 in parts and labour for the rebuilds

about 24 hours of my own labour which probably saved me a couple grand that would have been charged by the Dodgy Brothers Mechanics locally.

Well done!


I did the same mod when I was at Tindal back in 05 - best damn thing I ever did putting the Disco gears in


Only thing I did different was I changed the low range gears to a (then) set of Maxi-Drive straight cut gears. Again it was the best damn thing I ever did!


Cheers
Chris

Nice work.

Rgds
Pete

Great effort. I was gonna pipe up but then realised this is the end of the saga!!!

The newer cross drilled input gears engage on unused splines of the mainshaft. (You can see them in your picture of the flogged main shaft)
For a temporary fix you could have cleaned her up and whacked in a new cross dilled input gear. Wouldnt have fixed the clutch and rear main issues but would have been mobile!!!! Im still on such a temporary fix - for 3 years and 50 thou odd kays mostly up the cape getting a flogging.

I spose Ill stump up for some shiny bling like you have one day!

Steve