Thread: Gearbox gone BANG

Depending which checks were done, it could just be a drive flange on a back hub (quick and easy fix), but the other likely cause is the output gear on the back of the gearbox worn out the splines onto its shaft (much bigger job). There are other possibilities, but these are the most likely.

John

Originally Posted by SpammyG

managed to get it in 1st and idle up the rest of the hill


Sam

Doesn't sound like a drive flange ?

Assuming it is as suggested above the "output gear" actually is the transfer case input gear wearing on the gearbox output mainshaft - this is easy to check on a 96 defender

1/ remove PTO cover at back of transfer case.
2/Pry off the rear input gear race housing.
3/You will no be able to slide the input gear out and quite likely from your story you will have stripped out the splines of the R380 gear box mainshaft output.

Now the good news, assuming your 96 has not been altered (as in it is factory) you have a quick easy and relatively reliable short term fix. Source a new cross drilled input gear of the correct type.

The newer cross drilled gear engage on the entire mainshaft spline and with some cleaning of the main shaft you should be able to slide a new cross drilled input gear onto the shaft and bolt it all up.

Assuming this is your problem this will get you mobile again very quickly and cheaply.
The proper fix is to rebuild the R380 gearbox or source a newer one.

I drove around for about 40,000km all over the Cape on just such a temporary mod up until last weekend when I finally got around to changing out the gear bag and t-case

Steve

Did you engage centre diff lock and try drive as part of your diagnostic driving?

Sent from my GT-S7562L using AULRO mobile app

I had a similar problem about nine months back on another 96 130, left me stranded with no drive available at all. Ended up being an expensive exercise in my case with the main shaft snapped.
Fingers crossed yours is an easier fix.

Cheers

Thanks for the responses guys. Will have to try and get someone who knows what they're doing to have a look at it.

Originally Posted by SSmith

Did you engage centre diff lock and try drive as part of your diagnostic driving?

Sent from my GT-S7562L using AULRO mobile app

Nope, didn't try this. Didn't think it would matter if its a gearbox issue. Would this be to check if its a drive flange issue?

Sounds like you have torn the centre out of the clutch plate to me.

------ managed to get it in 1st and idle up the rest of the hill ------ We did some diagnostic driving which led to a whole bunch more clunking and a complete loss of all drive in any gear. When I lift off the clutch in gear, i hear a nasty grinding noise and get no drive at all. Possibly the input shaft?

.

Originally Posted by wrinklearthur

Sounds like you have torn the centre out of the clutch plate to me.


.

If that was the case would I still be able to get some drive if I could get it in gear and start it off the starter motor?

Anyone able to let me know what the approximate cost of a gearbox replacement or rebuild is?