TD5 R380 Lost 3rd Gear

[dayswaste]

Hello,
Last night I lost 3rd. Not sure where it went. Planning on replacing oil this weekend in case it shows up. Anyone have any pointers as to where it might be?

[TeamFA]

Behind the cushions on the lounge...??

Seriously, that does sound a bit odd. All other gears okay?

[CraigE]

Does not sound good.
can you engage 3rd gear when engine is off?
Maybe worn or damaged 3rd synchro or a selector rod issue.

Either way I would say will need to come out.
I recently lost all drive, and only ended up with 4th gear.
I have made the decision to get a fully recond box rather than try and rebuild atm.

Cheers
Craig

[TeamFA]

Awww... but such fun is to be had learning about the inside of your gearbox! I thoroughly enjoyed learning how to rebuild mine - even more so when it worked!

Yes, hopefully a selector issue only, but either way it would be a gearbox out job, I would think. I don't think there's much in the easily-accessible area on the top of the box that would give that symptom.

I'm sure somebody more knowledgeable will be along shortly...

[CraigE]

Awww... but such fun is to be had learning about the inside of your gearbox! I thoroughly enjoyed learning how to rebuild mine - even more so when it worked!

Yes, hopefully a selector issue only, but either way it would be a gearbox out job, I would think. I don't think there's much in the easily-accessible area on the top of the box that would give that symptom.

I'm sure somebody more knowledgeable will be along shortly...

Yeah, I have ordered an Ashcroft box and should be here in around 2 weeks, but will rebuild the old one given time, but will need to sort the correct tools etc. Gearboxes are not a thing I am confident with but with the right tools I am sure I can do it.
Having said that while I have the TC out I am contemplating changing the High Ratio gears out and replacing with 1.222 gears I have in another TC to make it nicer in 4th while towing on highway so I dont get tempted to use 5th again.

[dayswaste]

All other gears Ok. The selector feels like it's engaged, but no go, engine running or not. Just looking at the workshop manual now, hoping there’s enough access from the top without removal.

[CraigE]

All other gears Ok. The selector feels like it's engaged, but no go, engine running or not. Just looking at the workshop manual now, hoping there’s enough access from the top without removal.

No access to an R380 from the top. Sounds maybe like a selector issue or maybe synchro or something worse. To look internally the only option is to remove. It is possible to remove the trans case and then remove the extension house in situ, but much easier if out and on the bench.
Good luck as I feel your pain.

[dayswaste]

Thanks, doesn't sound promising. I started removing the interior for easier access and then guests arrived. I'm happy enough with the distraction as I'm not looking forward to resolving this issue. It might give me time to find this bench you're referring to.

[CraigE]

Mine was a bit involved as I have a floor safe under the console so most of the wiring for that had to come out first. I took the passenger side seat out for easier access, then the mats and tunnel. Then tails shafts, exhaust, transfer case and mount, starter motor, slave cylinder then gearbox and mount.
It will depend on what workshop tools you have. A hoist would be handy but can be done on the floor. The biggest issue is you will need to jack up the front end to get the bell housing out from under the car. I used an engine crane in through the door. You can use a trans jack, but you will definately need to lift the car to get out if you do as there is not a lot of room.

Previous post should have read examine and strip on the bench.

[Bundalene]

I replaced our daughters gearbox recently and had basic tools and equipment. I used 2 bottle jacks and heaps of wood blocks (there was nothing else available)

Other than general tools, I recommend - 10, 13, 15 mm 6 sided good sockets, spanner to undo the cooling lines off the gearbox and a correct size piece of broom handle to re-align the clutch.


Also remember to disconnect the crank angle sensor and oil pressure switch and engine fan before removing (If a TD5)

I found the most difficult thing was getting the gearbox back in - that last 3 inches

Good luck and work safely


Erich

[dayswaste]

Hi CraigE, How much was the Ashcroft box delivered if you don't mind me asking?

[Bundalene]

Sorry to but in:

Send Ashcrofts an Email, they are great to deal with. Here is a quote when we bought ours:


Hi

Thank you for your enquiry.

The price of the gearbox with the rear support bearing upgrade is £1,005 rebuilt outright plus £200 shipping to Sydney airport only. The shipping price excludes customs clearance costs, duty, taxes and local delivery costs.

We could ship out in 3-4 working days and the transit time is usually 5-7 working days.

Should you wish to return the old unit there would be a £350 refund on the unit price, provided it is as stated in the attached sales terms.

We look forward to hearing from you.



Kind regards
Julie Fryer

Ashcroft Transmissions Limited

Tel: 44 1582 496040

Fax: 44 1582 595040

Ashcroft Transmissions (http://www.ashcroft-transmissions.co.uk)



Customs, duties, GST ............... were another $400 plus. We picked up at the shipping agents - what a pain. I recommend getting a door to door quote.







Erich

[CraigE]

Hi CraigE, How much was the Ashcroft box delivered if you don't mind me asking?

Hi,
The quote is as follows.
845 GBP for the box outright (495 GBP plus 350 GBP for non return of box).
160 GBP for HD bearing upgrade.
250 GBP freight TNT door to door.
Total 1255 GBP or $2310 AUD approx.
There may also be some customs charges, not sure how much atm.
Cheers
Craig

[wrinklearthur]

Hi Craig

Do some reading on here about some of the freight companies not playing fair, it seems some do charge for the privilege of looking after your imported goods while Customs get their act together.

.

[dayswaste]

I'd be hoping the freight would come direct to Darwin through Singapore. Everything that arrives via Sydney seems to get stuck there for weeks.

[dayswaste]

I haven't found the gear, although I keep trying as if it will re-appear.
I've only removed the panels etc.. so far for access and haven't removed the box in case I decide I need to move to a workshop (all other gears work, not sure if they'll hang around though.)
I'm not likely going to remove it until I have a replacement.

Is it common to have gearbox issues around 150k?

[CraigE]

I haven't found the gear, although I keep trying as if it will re-appear.
I've only removed the panels etc.. so far for access and haven't removed the box in case I decide I need to move to a workshop (all other gears work, not sure if they'll hang around though.)
I'm not likely going to remove it until I have a replacement.

Is it common to have gearbox issues around 150k?

Mine had done nearly 200k. When I had the box out last year and engine to put in a new clutch and some other items the bearings etc all were fine. What has happened with my bearing is the retaining ring has snapped allowing the roller bearings to drop sideways. So far that is all i can see, but as it has done 200k I decided to replace the box.
Is there anyone local that may be able to take a look at it for you?
Cheers
Craig

[CraigE]

Hi Craig

Do some reading on here about some of the freight companies not playing fair, it seems some do charge for the privilege of looking after your imported goods while Customs get their act together.

.

Going TNT and by all reports are much better, but will have to see.

[dayswaste]

I'm just looking up local options this week, now that I have some references to go by. Thanks for the info, I'll be in touch.

[Jode]

Other than general tools, I recommend - 10, 13, 15 mm 6 sided good sockets, spanner to undo the cooling lines off the gearbox and a correct size piece of broom handle to re-align the clutch.
I used a deep socket (19mm? don't remember) on an extension for the alignment tool, and wrapped masking tape around the socket to get a very tight fit to the clutch. This worked fine.