Td5 flex plate

[bov17]

Hi everyone.

So. We have replaced the gearbox in the disco after it died. And all went well for about 80k.

It then proceeded to die again. So. Thinking it was a faulty box we replaced it AGAIN.

So after the second fitting of a replacement gearbox it all went well for about 90k. Same bloody problem. Just no drive in any gear.

So we checked thinking it could be the transmission coolet being blocked and preventing flow. We dont even have flow coming out of the box directly without the hard lines connected. And yes weve checked the fluid levels are ok.

My question would be relating to the convertor and flex plate etc. Everything lined up perfect when mating the box to engine. Bolted the convertor up through the starter hole and then the rest etc.

Question is how to we ensure the convertor is still located correctly in the box before bolting it to the flex plate? It seems that after inspecting the previous box there is a light score mark as though when we have bolted home the convertor it has pulled slightly back from the pump and eventually slipped and failed.

What else are we missing? Why does the convertor do this? Is there some kind of spacer missing behind the flex plate causing this?

Note: we didnt take the flex plate off at first failure however the mechanic did previously to us owning us and we had found it wasnt aligned correctly (couldnt remove convertor through the starter first time we removed box)

[discorevy]

Converter stack height for yours should be 96 mm , you should have a few mm free play when bell housing is bolted up , assume you've checked filter ? , are these recon or second hand boxes?, check you haven't got a partially blocked cooler or hoses

[alien]

Refitting links from The Good Oil....
http://www.aulro.com/afvb/good-oil/162286-joining-auto-torque-convertor-correctly.html

[steve_a]

When you fit the box up the flex plate should be about 2 to 3mm (I think the manual has the actual number) of space. Too much or too little and you can add or remove spacers under the flex plate.
Ashcroft supplied about 3 spacers with my new box.
It does mean that if you want to do it properly you need to offer the box up and be prepared to remove it to sort spacing out, then refit the box.

[Tins]

It does mean that if you want to do it properly you need to offer the box up and be prepared to remove it to sort spacing out, then refit the box.

Doing it two or three times when you've already got everything out beats the hell out having to do the whole job over again, IMO,:)

[Tins]

Ashcroft supplied about 3 spacers with my new box.


Steve, can you give me a rough idea how man $$ your box was landed at your door?

[steve_a]

There is a complete thread on it in the D2 forum here. Short version was about $4500 IIRC