130TD5HCPU Gearbox issue

[DizzyLimit]

Hi,
I have just bought a 99 TD5 Defender Dual cab and noticed the gearbox filler plug was missing as I crawled under the other day to service (was towed to my place). Went to fill with oil and as quick as it went in oil went out onto the floor. There are a few unknowns with this car as I am discovering. I know it had an engine change recently. The question is whether it is worth trying to remove the box myself (no hoist) or leave it to a pro (also suggest pls). Any ideas what the problem is likely to be? Thanks for any input. Cheers and thanks in advance.

[Toxic_Avenger]

I think not being able to hold oil is your number one problem off the bat.

Are there any other known issues other than the drain plug missing?

[cinders]

If you know of a reputable mechanic up that aways, might pay to take it to them for a good check over. Might cost a bit but at least you'll have a list of what's wrong and what you'll feel comfortable doing yourself

[DizzyLimit]

I think not being able to hold oil is your number one problem off the bat.

Are there any other known issues other than the drain plug missing?
I did drive it around the block (with no oil in it) and it seemed to perform ok so at this stage just need to get the gearbox issue sorted but cant afford the $1000 quoted to remove and refit (without fixing the actual issue. I will pull it out myself (and get someone to sort the issues out) but just want to know what I am in for. If I can save on a fair bit of the labour I will. Cheers

[2stroke]

You can pull the transmission at home without a hoist, I removed the floor (good time to address any rust where it bolts in) and used an engine lifting crane through the front door to raise / lower it. Much safer than getting under it.

[dromader driver]

I agree with 2 stroke. Can be done with engine crane in door. Eventually need it a bit higher to move out from under the vehicle.

About 4 hours work plus time spend on removing corroded floor fastenings.

[Pacemaker]

Hi Dizzylimit

How long have you owned the 130 for?

Cheers
Michael.

[jboot51]

Where on the box was the oil escaping ?


So there is a drain plug installed but no fill plug ?


Driving a R380 with no oil would be terminal as they have an oil pump in the box.


Due to the value of vehicle vs cost of repairs I think you should have a go at it yourself. DIY is the only way to go.


There are drawings around for a bracket that bolts to the transfer case, it would allow the use of a trolley jack for gearbox removal.

[CraigE]

I have just done it in my garage to replace the box. It is a PIA but can be done by any semi competent person, just takes time and a lot of stuffing around. You can do it easily with an engine crane and a couple of slings. I removed the trans case and then the gear box.

[DizzyLimit]

Hi Dizzylimit

How long have you owned the 130 for?

Cheers
Michael.
2 months, what have I done, what have I done?? ha

[DizzyLimit]

Where on the box was the oil escaping ?


So there is a drain plug installed but no fill plug ?


Driving a R380 with no oil would be terminal as they have an oil pump in the box.


Due to the value of vehicle vs cost of repairs I think you should have a go at it yourself. DIY is the only way to go.


There are drawings around for a bracket that bolts to the transfer case, it would allow the use of a trolley jack for gearbox removal.


Yes I have gathered as much after talking with various "land rover experts". It should have tweaked when I saw the filler plug missing!!
Anyway, would the order of events be 1. Crossmember remove, 2. Transfer case remove, 3. Floor remove 4 Gearbox remove ??

[DizzyLimit]

Where on the box was the oil escaping ?


So there is a drain plug installed but no fill plug ?


Driving a R380 with no oil would be terminal as they have an oil pump in the box.


Due to the value of vehicle vs cost of repairs I think you should have a go at it yourself. DIY is the only way to go.


There are drawings around for a bracket that bolts to the transfer case, it would allow the use of a trolley jack for gearbox removal.


It is pouring straight out of the slot as can be seen in the pic below

[Duarte19]

It is pouring straight out of the slot as can be seen in the pic below


that looks like your wading plug, nothing to worry about

more than likely its the input shaft seal leaking if it coming out if that hole

[DizzyLimit]

that looks like your wading plug, nothing to worry about

more than likely its the input shaft seal leaking if it coming out if that hole

Ok Thanks for the reply. Makes me feel a little better but I am fully expecting the worst. I will pull out the box/transfer and as others have suggested address any other issues while I am at it, clean everything, get the box checked for issues (if possible) and reassemble with new input seal. I will allow 2 weeks of hard work and raised tempers. I will document the process for all to see. Cheers.

[jboot51]

Do you have a shed to work in. (air conditioned would be nice)
If so, I don't have a lot of free time but might be able to lend a hand.
I can borrow an engine crane short term.

[DizzyLimit]

Do you have a shed to work in. (air conditioned would be nice)
If so, I don't have a lot of free time but might be able to lend a hand.
I can borrow an engine crane short term.


Thank you for offering JBoot51, you are a champion, should be more like you but there has been a development... I have to say I feel like an idiot but all is good, it would seem that the timing port hole on the BELLHOUSING!! is not the best place to try and pour gearbox oil into. Yes I discovered this after doing what I should have done in the first place and checked out the procedure on YT. I took it round the block again yesterday, got everything to operating temp and drained diffs, box and transfer- and boy did they need it. But lets stay in touch I am down the coat often and will call in and show you the Beast! Cheers :wasntme:

[jboot51]

Good to see you got it sorted.


You learn something new everyday.

[CraigE]

Thats a wading plug. It may also be a rear main seal. Can you determine if it is gearbox oil or engine oil? The drip looks a little dark to be trans oil.
If you dont have a Rave manual get one as it helps a lot. If you need it urgently let us know and I will see if I can print out and scan the sections you need and email. Sorry assuming TD5 but should not be much different.
There is a specific sequence, but a lot of stuff can be done in any order.
Air box will need to be removed so you can get to the top bellhoousng bolts,
Remove tails shafts.
Remove centre pipe exhaust and front pipe.
Remove cross member.
Remove gear sticks.
Remove console and floor panel underneath.
Remove tunnel.
Disconnect all elec plugs to box and Crank Angle sensor to bellhousing.
Remove handbrake cable.
Remove starter motor.
Unbolt earth points on gearbox and trans case.
Remove clutch slave cylinder.
Disconnect linkages between gearbox and trans case.
Sling trans case to engine crane.
Undo and remove drivers side trans case mount and remove taking up weight on trans case.
Unbolt trans case from gearbox.
Slide trans case back and lower to floor.
Once done set up crane and slings to gear box.
Unbolt bellhousing bolts and take up weight. Slide gearbox back an lower.
You may need to jack up the car to get boxes out from underneath.
This is just from memory.
Can be done in about 1/2 day easily at a reasonable pace. About same to put back in.

[stewie110]

Thank you for offering JBoot51, you are a champion, should be more like you but there has been a development... I have to say I feel like an idiot but all is good, it would seem that the timing port hole on the BELLHOUSING!! is not the best place to try and pour gearbox oil into. Yes I discovered this after doing what I should have done in the first place and checked out the procedure on YT. I took it round the block again yesterday, got everything to operating temp and drained diffs, box and transfer- and boy did they need it. But lets stay in touch I am down the coat often and will call in and show you the Beast! Cheers :wasntme:

I had the same panic attack (see previous threads with photo in this forum) a few years ago.. The only difference is that I didn't try and put any oil in.