UK replacement LT95A options failed synchro

[alexp789]

Hello all!
It's my first post here after becoming a recent happy owner of a 1989 Perentie FFR imported to the UK from Australia.

Really enjoying the vehicle, however am worried about impending gearbox doom. It has an LT95A gearbox (I've struggled to find the serial on the box, but visually matches) but appears to not have any hint of ever having a synchro. I've developed my double clutching skills but am worried about it's longevity.

Having rung around in the UK I've struggled to find anyone interested in rebuilding the box and so am left considering options.

Things I'm considering:
1) Keep searching for replacement LT95's. Likely to be LT95 rather than LT95A.
2) Look into mating an R380 to the 4BD1.

Other options? Would love to know people's thoughts and insights.

Thanks in advance!
Alex

[V8Ian]

Have you tried Ashcroft, for a rebuild or exchange?

[p38arover]

If you were here in Oz I’d recommend either KLR Automotive klr.com.au or Bearman on this forum to do a rebuild.

KLR definitely have syncro rings and other parts in stock. They specialise in the Perentie.

LT95 parts (https://klr.com.au/search-results-page?q=Lt95)

They also have an LT95 bellhousing exchange for one modified for the R380. The hole has to be filled in and a new hole to suit the R380 machined in. Ut it isn’t heap!

Bellhousing, 4BD1 LT95 to R380 - LT95-R380 (https://klr.com.au/land-rover/perentie-and-110/perentie-4x4/spares-and-parts/engine-and-drivetrain/gearbox-transfer-case-and-winch/bellhousing-4bd1-lt95-to-r380/)


Their email address parts@klr.com.au

They ship worldwide.

[alexp789]

Have you tried Ashcroft, for a rebuild or exchange?

Thanks V8Ian, I did, unfortunately they advised they're no longer working on LT95 gearboxes, and have recommended another place I'm going to call later today (I'll update the thread with their details if there's any luck there)



If you were here in Oz I’d recommend either KLR Automotive klr.com.au or Bearman on this forum to do a rebuild.

KLR definitely have syncro rings and other parts in stock. They specialise in the Perentie.

LT95 parts (https://klr.com.au/search-results-page?q=Lt95)

They also have an LT95 bellhousing exchange for one modified for the R380. The hole has to be filled in and a new hole to suit the R380 machined in. Ut it isn’t heap!

Bellhousing, 4BD1 LT95 to R380 - LT95-R380 (https://klr.com.au/land-rover/perentie-and-110/perentie-4x4/spares-and-parts/engine-and-drivetrain/gearbox-transfer-case-and-winch/bellhousing-4bd1-lt95-to-r380/)


Their email address parts@klr.com.au

They ship worldwide.

Thanks p38arover, I dropped them a note, they've confirmed they can ship to the UK, but have no distributors here. I've got the car going into a local Land Rover specialist for a general once over in a couple of months - so will get their thoughts too. I'm going to do some research on the bellhousing required to pair an R380 to see if there's a route to sourcing/making one locally as price for shipping (especially considering the return) will be pretty punchy.
On the LT95 rebuild I'm not against that, but it seems parts are pretty scarce here, so I'm concious of taking it off the road and entering into a bit of a one-way street with it. One option is to look for a salvage (not reparable) LT95 and strip it down to gain confidence on rebuilding it myself I guess, then ordering plenty of parts and cracking on with the proper rebuild - should be educational if nothing else!

Thanks for the thoughts so far all, and definitely open to any other options / ideas people have.

Alex

[Fattima]

A quick Google bought this mob up
R Whitehouse and Son | LT95 Reconditioning Specialists (https://www.whitehousegearboxes.co.uk/lt95-gearbox.php)
I bought syncros for mine from the UK, so parts should be available there.

[powerband]

I had an LT95 that was similar sounding to yours. Double clutching etc., could only really get 4th.
Changed the oil to auto transmission fluid, problem solved, still going well 180.000 ks later.
Paul.

[p38arover]

Good point. What oil are you using, Alex? If I recall correctly, the LT95 uses a lightweight oil.

[123rover50]

I use 15-40 engine oil . Only have to carry one sort of oil then when going bush.
I bought two rebuilt transfer boxes from Ashcroft and he specifies ATF for them.

[alexp789]

Thanks everyone for the pointers. I've changed the oil in the gearbox and transmission. I've used 10W30 semi synthetic, I would've used mineral oil but couldn't get it at the time, so figured fresh oil was better than the unknown that was in it.



I had an LT95 that was similar sounding to yours. Double clutching etc., could only really get 4th.
Changed the oil to auto transmission fluid, problem solved, still going well 180.000 ks later.
Paul.
This is interesting, from the forum I'd heard lots of points about /not/ using gear oil in the boxes - I'll do some more reading... I'll try and record a video of it in action and compare notes further 🤣

One of my biggest challenges is that I don't know whether this is "just how the boxes are and you need to change slower, do this" or actually there's a repair needed and it's worth the investment to not do damage from the odd time my double clutching skills fail me?

Been out today and had an awesome time, so definitely want to keep it going in good health!

[p38arover]

I use 15-40 engine oil . Only have to carry one sort of oil then when going bush.
I bought two rebuilt transfer boxes from Ashcroft and he specifies ATF for them.

Doesn't oil migrate from the gearbox to the transfer case?

KLR Automotive sell a kit which I think is to mitigate this. If the fluids are different, that would be an issue with them mixing. Am I wrong as to its purpose?

LT95 Transfer Case Oil Balance Hose Kit - KLR-OBL (https://klr.com.au/land-rover/perentie-and-110/perentie-4x4/spares-and-parts/engine-and-drivetrain/gearbox-transfer-case-and-winch/lt95-transfer-case-oil-balance-hose-kit/)

[123rover50]

Doesn't oil migrate from the gearbox to the transfer case?

KLR Automotive sell a kit which I think is to mitigate this. If the fluids are different, that would be an issue with them mixing. Am I wrong as to its purpose?

LT95 Transfer Case Oil Balance Hose Kit - KLR-OBL (https://klr.com.au/land-rover/perentie-and-110/perentie-4x4/spares-and-parts/engine-and-drivetrain/gearbox-transfer-case-and-winch/lt95-transfer-case-oil-balance-hose-kit/)


Yes mine migrates so I made my own balance tube setup. 15-40 in engine , g,box and t,box. Its an ex Army LT95 A I got from the auctions and swapped out the early one I had.

The Ashcroft T,box I mentioned is the one behind the LT77. I think its an LT 230 behind my two 200TDI,s. So I have two different oils there with ATF in the T,box

[123rover50]

For those that have not seen one.
https://live.staticflickr.com/65535/53840428803_be85219668_c.jpg (https://flic.kr/p/2q2GgHe)IMG_2871 (https://flic.kr/p/2q2GgHe) by Keith Cree (https://www.flickr.com/photos/141809689@N05/), on Flickr

[alexp789]

Yes mine migrates so I made my own balance tube setup. 15-40 in engine , g,box and t,box. Its an ex Army LT95 A I got from the auctions and swapped out the early one I had.

The Ashcroft T,box I mentioned is the one behind the LT77. I think its an LT 230 behind my two 200TDI,s. So I have two different oils there with ATF in the T,box

This is going to sound like a really silly question, but how did you determine it was migrating? Low oil level in the gearbox and the tranfer case becoming over-full?

Now for the section where I really embarrass myself! Part of the challenge I have is that my head is saying "the gearbox isn't right", however I've not got access to any other vehicles with older gearboxes like the LT95. As such, once you've finished laughing at me filming this, and asking questions, here we go!

https://youtu.be/sF20nkmJDss



Going up the gears, this is as fast as you can change without then crashing really harshly. Is this normal?
When shifting down gears, such as this into second if I don't double clutch like this it would grind badly, I assume this isn't normal?
There is a notable extra noise from the vehicle when in neutural and the clutch out, I assume this is just normal noise of the gearbox turning.
Not really a question, same point as 1.
Shows a gear change 2->3 which I did too quickly and so crashed in. Should I be able to change this quickly, or am I expecting too much?
Shows a change 3->2 whilst slowing down, and you can't get second without double clutching the box. (I mean I could've crashed it in, but my double clutching practice is paying off)
Same as 5. changing 2->3 too quickly causes it to crash in. Normal?


Just to say thanks again to all for helping out someone new to the joys of Perentie ownership! For what its worth I'm not a complete idiot, I have figured out the diff-lock is in fact working, for some reason the switch on the transfer case isn't connected to anything, so I'm going to have to do some wire tracing to figure out whats gone awry there.

Thanks all!

Alex

[workingonit]

...how did you determine it was migrating? Low oil level in the gearbox and the tranfer case becoming over-full?

I'm speaking from the experience of owning a Toyota Troop Carrier. Similar issue. Transfer case overflows through the breather, blows out from under the vehicle and all over the rear window. Of course you pull over wondering what the heck is going on. As you have reasoned, stick you finger in the gearbox filler and feel no oil. Undo the transfer case filler and oil gushes out. In the case of the Toyota the cause is a worn seal between the gearbox and transfer case. The obvious solution is replace the seal - the easy solution is a bypass hose - or do both! I remember reading somewhere the problems are compounded where vehicle design has a transfer case sump sitting lower than the gear box sump - better design has the two sumps at the same level with easy flow between the two units. Won't go into the effort required to find enough replacement oil in a small outback town.