L Series drops out of 5th on over-run.

[LRT]

I've recently purchased a good condition Freelander 1 L-series diesel with the 5 speed PG1 gearbox that has done 290,000km.

When up shifting it works fine, but on over run it drops out of 5th but will stay in with light pressure on the gear stick. Also worth noting, is when down shifting from 5th, it is extremely reluctant to go into 4th even if you try double declutching. If it doesn't pop in it grates and will only go in (albeit stiffly) if you go back to 3rd and back into 4th. The clutch was replaced 10,000 km ago.

The other problem is a grinding/roar sound of either a damaged bearing or CV joint that is only apparent when in gear. With the clutch down coasting it doesn't make any sound. There is also a howl from the rear of the car but it could just be the aggressive pattern Continental tyres. The VCU isn't fitted so it is obviously not part of the problem.

Definitely the Morris/Perkins/Rover L-series sounds more Land Rovery compared to the later BMW Td4!

[LRT]

Another symptom is a hardly noticeable main shaft chatter when idling that disappears when the clutch pedal is depressed. Sounds like a very quiet version of the typical old Defender mai shaft chatter at idle. Something that I'm well accustomed to! 😀

Should I be getting another box from a wrecked K series F1?

Also, should I put in MTF 94 oil or just run ATF?

[LRT]

It is increasingly getting harder to select 4th gear above 40kph without grating.

I drained the gearbox oil and there is evidence of brass material in the oil. The oil level was correct.

I refilled it with Castrol Syntrans 75W/85 and the noise has hushed a little but doesn't make gear selection any easier.

See pics below:

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[LRT]

Here's a link to a recording of the Freelander starting off in 1st then changing to 2nd and 3rd and coasting in gear. Then it shows the sound in reverse and back to first.

Dropbox - New Recording 144.m4a (https://www.dropbox.com/s/u0ycw2tf37po7wo/New%20Recording%20144.m4a'dl=0)