Td5 manual gearbox woes

[Markf]

Hi all,
Just got back from a trip that went NOTHING like the plan. Weather gods decided we hadn't offered the correct sacrifices at the right time or something.... Got to Oodnadatta OK but then....


To the issue.


Around 800k's ago the gearbox started to make a sort of clunky, ringing whine in 2nd, 3rd and 5th gear which is getting worse. No noise in 4th. I suspect the internals of the box now look something like what's shown here http://www.aulro.com/afvb/technical-chatter/166433-r380-rebuild-after-5th-gear-failure.html or worse.


Seeing I don't have the facilities, the space or the tools to rebuild the box myself I figure I have two options. Get the existing box rebuilt here in the Latrobe Valley (Vic) by what used to be Massaro's or get them to fit an already reconditioned box that I'll get from somewhere.
What would be the best suggestion ? If it's to get a reconditioned box from somewhere, where would be the best and what sort of cost supplied and fitted ? If it's to get the old Massaro's to rebuild it, what sort of cost would I be looking at ?


Thanks for all advice...:-)


I'll post a couple of pics of car pre and post Oodnadatta to Marla in the pics thread when I get to it - gotta get rid of some of the red dust from everything first. I'd forgotten how red dirt proof Land Rovers aren't...:-)) Camper trailers let it in too - at least ours does.

[DazzaTD5]

I guess it comes down to time, money, trust in the repairer....

While I have rebuilt Gearboxes for many years myself (as it was the trust issue of getting others to do it) I simply don't have the time resources to do it now.

I recommend for a trusted source to get a box from Ashcroft Transmissions in the U.K and have someone locally fit it for you.

http://www.ashcroft-transmissions.co.uk/manual-gearboxes.html

Regards
Daz

[justinc]

We don't rebuild anymore either as it is just uneconomical in time vs return. As Darren said either Ashcrofts ( which we have never had an issue with their stuff) or a 'local' shop that we use in Sydney Award Diffs who also do in warranty stuff for landrover incidentally.

Jc

[laney]

I would go Ashcroft as they upgrade the main bearings to heavy duty I had my original d2 box rebuilt never again cost about $6000 fitted Ashcroft would have cost less and be way stronger.

[Markf]

I would go Ashcroft as they upgrade the main bearings to heavy duty I had my original d2 box rebuilt never again cost about $6000 fitted Ashcroft would have cost less and be way stronger.

Looks like the Ashcroft option will be the way to go. Gonna be a pain though - the Disco is my daily drive so a hire car will be required which will up the cost a bit. Today I shall grovel under the car and get the grabox serial number and do the ordering thing. Does anyone have an idea of the time it'll take to get here ? Answering my own question (in part) I guess it all depends on the freight options - there's bound to be one that gets it here before I order it but it'll cost a right arm, left leg and first born and another option that'll take until at least the next ice age...:-)


Are there any well known pitfalls with freight, customs and AQIS ? I'd like to steer clear of 'em if possible.


And while the box is out the CDL selector can be installed as well - will get the Ashcroft bits sent as well. Transfer case has the innards so the selector is all that's required.

[steve_a]

I had an autobox sent over last July or so.

1/ Source a box on ebay in the UK and get sent to Ashcrofts to avoid the core charge. Never looked at the price for the manual, but it will likely save about 1/2 the core charge.
Do this first so that the import costs don't include the core charge.

2/ We used DHL. We got stung by DHL, NOT CUSTOMS, DHL, for BS charges. Verify with Ashcrofts and DHL that the price paid is the price paid. I ended up with another $400 of DHL made up crap on my bill. And DHL don't respond to complaints...

3/ Customs and AQIS will be involved as it will be over a $1000 and will come in a non-discreet form :) Get a broker to do it, I had a look at doing it myself, but to be honest it was easier to have them do it, I think that was about another $200.

I have a thread with the exact costs in it on here.

If you aren't doing any other mods a new box can be in and out in a day, at home, in the garage. Is the manual cable selected or still mounted to the box? If mounted then you have to do the centre console out, otherwise you might be able to do it from underneath only.

Don't forget to think about ordering some other stuff while you are there and it makes sense.
Dual mass flywheel
clutch kit (friction, pressure and release bearing)
heavy duty fork

[Bohica]

Does anyone have an idea of the time it'll take to get here ? A

I ordered engine mounts from the UK, they took 6 days to get here. Air freight is quick, and expensive.
Ask Ashcroft, they should know.

[ozscott]

Interesting. I had a reputable LR indy overhaul the 5 speed (v8 but same box) and transfer case and put in a new clutch for a lot less than that. it had an ashcroft synchro kit put through the 5 speed box, kit through ttsnsfrr case, new bearing on 5th, new layshaft bearings etc in the TC, throw out bearing for clutch and some other stuff. All up about $4k.

Cheers

I would go Ashcroft as they upgrade the main bearings to heavy duty I had my original d2 box rebuilt never again cost about $6000 fitted Ashcroft would have cost less and be way stronger.

[stewie110]

The eBay to ashcrofts is a good idea. I wish I had done that when I replaced the one in my td5 Def.

[CU55TM Disco]

I just bought some stuff from DLS, they traditionally use DHL to freigh @ $?75 for 20kg
They trialled TNT as a cheaper option, ?35 for the same weight. 6 days from collection to doorstep as promised and as tracking suggested.

[Markf]

The Disco is now at VSL (Massaro's) waiting on a reco box from 4wd Industries - they use the Ashcroft bits when they reco the boxes so it should all be good. Price worked out quite a bit cheaper than the Ashcroft option. A good deal faster too especially taking into account the little mandatory customs "holiday". I'm also getting a CDL kit from Les Richmond fitted at the same time. Again, this worked out cheaper and faster than the Ashcroft option.
Should all be good when I get it back in a week or so...:-)

[Markf]

Well my car is still at VSL.
The withdrawal symptoms are getting quite severe.
The holdup was 4WD Industries having to wait for parts from Ashcroft. They sent the gearbox to VSL last Thursday (24/04) so it shouldn't be too long now. I'll have a rebuilt gearbox, new clutch, a CDL linkage and it will have had various other bits done when I get it back...:-)
In the meantime I'm scooting around in a LITTLE VW Polo which is auto and I HATE little cars. Especially automatic ones...:-(

[Bohica]

The withdrawal symptoms are getting quite severe.
I HATE little cars. Especially automatic ones...:-(
I know the feeling, my Disco went in on Thursday morning, back Tuesday Arvo. I have an auto Toyota Echo I can drive, but I walk to the shops.
Only 54 hours to go!!

Cheers

Julian

[Markf]

Well my car is still at VSL.

In the meantime I'm scooting around in a LITTLE VW Polo which is auto and I HATE little cars. Especially automatic ones...:-(

I've finally got my Disco back - no more LITTLE AUTOMATIC cars for me...:-)
I have a rebuilt gearbox, CDL linkage, new clutch (all of it), oil pump bolt locktighted, new rear main seal, a refreshingly quiet ride and a tailgate door that I can't open either from the inside or outside. The dust and mud from our aborted trip to the SA outback has probably set like concrete made with Araldite. It would seem that my next job is to get the mechanism out and give it a thorough bath and lube.. I've got no idea how I'm going to accomplish this yet but I'm sure a good search here will yield some good ideas...:-)

[4runnernomore]

Keep us updated on how it goes. were they able to fit the heavy duty bearings that also requires machining?


My gearbox is getting dodgy as well and I am starting to look at options?

Cheers, Chris

[Markf]

Keep us updated on how it goes. were they able to fit the heavy duty bearings that also requires machining?


My gearbox is getting dodgy as well and I am starting to look at options?

Cheers, Chris

If you've got the time available (car still drivable) I'd go the Ashcroft option. My car wasn't drivable and the extra expense the wait would've caused would've added considerably to the cost.


I believe that the bearings have been replaced with the heavy duty ones from Ashcroft. The synchro's are also the Aschroft articles.


I haven't tackled the tailgate door yet - that's the project for the weekend. I've also got to clean the kilo's of red dust from the interior - there's a cart load of it....

[DiscoDB]

I haven't tackled the tailgate door yet - that's the project for the weekend. I've also got to clean the kilo's of red dust from the interior - there's a cart load of it....

Speaking of a tackling, try giving the rear door a real solid hit from the outside. Chance are the latching mechanism has not seated properly and a firm hit should sort it.

[Markf]

Speaking of a tackling, try giving the rear door a real solid hit from the outside. Chance are the latching mechanism has not seated properly and a firm hit should sort it.


Real solid hits from the outside didn't work. BUT. A few REALLY solid kicks from the inside did. LOTS of REALLY solid red dirt in the mechanism. Now that it's open it's vacuum cleaner time...:-)

[Markf]

Real solid hits from the outside didn't work. BUT. A few REALLY solid kicks from the inside did. LOTS of REALLY solid red dirt in the mechanism. Now that it's open it's vacuum cleaner time...:-)


Well after getting the door open and messing around for ever I got the mechanism out and cleaned. There was a big heap of red dust that had congealed with any stray water or lubricant in there. It's a wonder I was able to get it open at all. All nice and clean and lubricated with lithium grease SPARINGLY and it works like a charm...:-)


Car's all nice and clean inside and out now...:-) All ready for the next adventure.


As a side note. Discovery 2's are certainly NOT dust proof...:-)

[R2D2]

As a side note. Discovery 2's are certainly NOT dust proof...:-)[/QUOTE]
I could not agree more.
My D2 is by far the worst sealed car I've owned. And I've had some pieces of crap.
The panel gaps aren't measured in mm. They are measured in cm!

[schuy1]

Funny, since I blocked off the "flow through" air vent in the DR quarter panel mine is really good for dust. Try a playdough for real dust ingress!:D

[ozscott]

Mine is blocked off too...because i run LPG and the vent for any leaks is that side....dont want to vent and then have it come back through those slats. Mine is very good dust wise since then. The rear door lock is a worry if you have a cage....

Cheers