Td5 defender r380 gearbox failure. Help.

Adjusted the clutch push rod. There was no free play so backed off the two lock nuts to give 1.5 to 2mm play.

The aircon had blown the 20 amp ac clutch fuse. Replaced the fuse and all is working fine. I used a nanocom to test the ac clutch switch and it tested ok. No obvious issues with the wiring loom. No idea what caused the fuse to go.

I will give it a run tomorrow and see how it goes.

Transfer isn’t using much oil now which is nice.

I have booked the 130 in with Dave Dover in Perth on Tuesday. Sounds like he knows his stuff. Very helpful on the phone.

Thank you all for your help. We will make it to Perth yet!

Thanks for the updated.....

Also check out the Defender WA facebook page. Not sure how long you will be in WA, but there are occasional meetups. Plus a lot of people willing to help out a stuck defender driver.

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Originally Posted by clintooo

Also check out the Defender WA facebook page. Not sure how long you will be in WA, but there are occasional meetups. Plus a lot of people willing to help out a stuck defender driver.

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I just sent a join request to their page. Thanks.

Glad to see you made it to Norseman. We stopped at Streaky Bay and now at Eucla, so it seems we won't catch you up as we turn South at Norseman. Safe travels. David

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Originally Posted by DeeJay

Glad to see you made it to Norseman. We stopped at Streaky Bay and now at Eucla, so it seems we won't catch you up as we turn South at Norseman. Safe travels. David

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Might catch you yet. As it is Easter and workshops in Perth are closed till Tuesday we headed south too.

Staying at Esperance tonight. Glad we did. This coastline is amazing.

The 130 is back on the road today. It spent the week with Dave Dover. Test drive and inspection from Dave and he recommended a remove and replacement gearbox.

Transfer seal replaced again and he used some green lock tight with the new seal.

He thinks there is something majorly wrong with the way this box was assembled from day 1. It had made some serious steel between port Lincoln and Perth. Replaced with a genuine LandRover reconditioned box from rover craft.

Serious dent in the bank account now...

Checked things over in Geraldton on Sunday and found the transfer case still with a major oil leak.
I contacted Dave Dover and he was sure it must be the intermediate shaft oring.

He booked me in for this morning and said he would reseal the transfer and have it back on by lunch.

So back to Perth.

Transfer out and diagnosis is major damage due to driving on tarmac in diff lock. New transfer case required.

So now waiting on a recon box from Melbourne through rover craft $$$.

We are about $11K into this repair now and nearly 5 weeks in workshop time out of our trip.

Now we need to make the decision of continuing the lap or just heading home.

i've got a TC if you want to take a punt on a second hand one as a cheaper option. It's out of a D2 though so will have slightly taller gearing. Dave may be able to swap out the ratios in your TC if they are ok.

I'm in perth. Dave knows me (I pull D2s apart as a hobby).

I understand your frustrations, but looks like you will have it sorted shortly. Then you will have this pain behind you. It's coming up to the best time of the year to head into the North West. You don't want to miss it mate, you have gotten this far....

Clint

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Originally Posted by clintooo

i've got a TC if you want to take a punt on a second hand one as a cheaper option. It's out of a D2 though so will have slightly taller gearing. Dave may be able to swap out the ratios in your TC if they are ok.

I'm in perth. Dave knows me (I pull D2s apart as a hobby).

I understand your frustrations, but looks like you will have it sorted shortly. Then you will have this pain behind you. It's coming up to the best time of the year to head into the North West. You don't want to miss it mate, you have gotten this far....

Clint

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Thanks Clint. I considered the secondhand d2 option but Dave talked me out of it pretty quick. I have had so many issues I had better get it done right with a recon transfer.

I think the ratios probably would be too high for my rig and my gear set was very sloppy. If rovercraft don’t come through with the goods I will be in contact though.

You are right about continuing north. It will be a bit of a rushed trip but that’s life. I am just paranoid about braking down along way from anywhere now. Ok if it was just me and my wife but we have my 2 yo and 7 month old to think of.