LT77 to R380

[cowboycammo]

hey all
just a quick series of questions for you

the LT77 gearbox in my 94 200TDI defender is on its way out. synchro in second is gone and the output shaft is severely worn

i have decided to replace this gearbox with an R380
i know this can be done, and so i was just wondering:
has anybody done it in a defender?
if so, what's involved? will i need a new bell housing etc

defenders have shorter input shafts than discoveries as i understand it, so it has to be a box from a defender.

any help/thoughts on the matter would be greatly appreciated

[Defender200Tdi]

None of the factory built R380s will fit your 200tdi Defender. As you rightly point out, the input shaft is about 5" too long for the R380 to fit. Defender R380s have long input shafts like a Discovery. In Australia only the 200tdi Defender LT77s had the very short input shaft arrangement.

The only solution is to source one of the rare aftermarket short input shafts for the R380 and use your existing LT77 bellhousing. The aftermarket short shaft was made by Ashcroft Transmissions in the UK for a while. They may be able to find one for you over there, but I imagine the cost would be rather exciting, not to mention the freight to Australia.:eek: Of course you'll then have to find a Defender R380 and have it stripped down and rebuilt with the short shaft.

You're probably better off getting your LT77 rebuilt. I know it's a crap gearbox, but an R380 is only slightly less crap and for a lot of $ to make one fit.

Paul:)

[emerald]

I am about to begin restoring an early 110, its getting a 200tdi engine and a suffix L R380 (Latest spec) and the gearbox is coming with a bell housing that allows it mate to the engine without any drama. Yes it is a Defender gearbox and its a factory item.

Fitting a disco gearbox is possible and you will have to fab up custom rods to allow the gearstick stay in the normal position.

A few times a year these R380's come up and this one is coming from Ashcroft Transmissions in the UK. Its a brand new unit and is untouched by Ashcroft, they are simply making life easier for me by making it available to me for less money than the main stealer. And also rebuilding my transfer box while I wait with cheque book in hand.


Emerald

[Defender200Tdi]

I am about to begin restoring an early 110, its getting a 200tdi engine and a suffix L R380 (Latest spec) and the gearbox is coming with a bell housing that allows it mate to the engine without any drama. Yes it is a Defender gearbox and its a factory item.

Fitting a disco gearbox is possible and you will have to fab up custom rods to allow the gearstick stay in the normal position.

A few times a year these R380's come up and this one is coming from Ashcroft Transmissions in the UK. Its a brand new unit and is untouched by Ashcroft, they are simply making life easier for me by making it available to me for less money than the main stealer. And also rebuilding my transfer box while I wait with cheque book in hand.


Emerald

If you fit a Disco R380 to a 200tdi Defender, then regardless of how the gearshifts work out, won't you also have to extend the front propshaft and shorten the rear propshaft?

Are there clearance issues with the long bellhousing in the 200tdi Defender floor/bulkhead?

How do you manage to swap around the trans box lever and gearbox lever to get them back in the Defender place/order? Any photos?

[modman]

i know of 2 lt 77's surviving behind 2.8 tdi's no probs.
are you sure that a rebuild and strengthen will not suffice. you are throwing a LOT of money at a box only marginally stronger at best. there are many upgrades available for the lt77, cheap and useful during a rebuild.
i know you pays ya money and ya gets what ya want, but it may be even cheaper to put a 300/r380 in.
if you go ahead with the swap it will make an interesting thread to post.:cool:
david

[cowboycammo]

are you sure that a rebuild and strengthen will not suffice. you are throwing a LOT of money at a box only marginally stronger at best. there are many upgrades available for the lt77, cheap and useful during a rebuild.
david

rebuild and strengthen? how would one go about strengthening?
and what are these numerous upgrades?
i know of a splash feed system that bolts into the rear of the transfer case (where existing cover plate resides now) but i haven't heard of many others. to rebuild is an $1800 job in parts anyway (includes all internals) but is still cheaper than the $2500 i was quoted for and R380 built to fit my vehicle.

$2700 sees the job done, and me not getting a finger dirty...and it would give me time to get reaquainted with the old truck...

what are peoples thoughts on this?
and please, more on those upgrades? i am intrigued..

[emerald]

No not quite mate, when I buy a gearbox I always go for one that fits as intended from the factory. So a defender R380 every time. You can go with a disco one if you have one there, but christ its a lot of work.

There are pics some where around here, I will try and find them. Its ugly and only done if a guy is badly stuck.

Emerald

[cal415]

Gday,
I have a LT77 from a 87 2.5D, not sure of condition etc but it might be the same setup as the box you have, Located in newcastle too and i am looking to get rid of it. Let me know if your interested.

[Defender200Tdi]

So I take it we all agree that fitting an R380 into a 200tdi Defender in Australia is pretty much out of the question? Importing the necessary short input shaft version or parts from the UK would be ridiculaously expensive.

Fitting a 300tdi length Defender R380 would mean major re-engineering of the driveline (i.e. moving the engine forward about 5").

Fitting a Disco version anything sounds like it's just plain silly.

Sadly, the only sensible solution is to rebuild the LT77s.:(



Paul

[Larns]

I don't think the input shaft would be nearly as expensive as everone thinks.
I was looking at getting the input for an R380 sent over and it was around the $200 mark(including postage). where as the same shaft in Australia was $700!!!!
Have a shop around, I think you'd be suprised.

[master chief]

Hello All,i reckon you are much better of rebuilding the 77 they are a top box,i know there are plenty of people out there who will disagree!.i have run one for years and never had trouble,drilling the output gear will fix most of the shaft wearing problems as it lets the oil in.they wear cause they run very dry.Long live the LT77!LOL:)

[rick130]

just thought I'd dredge this post up with a link to the gearbox Emerald is talking about from Ashcrofts. £825 outright.

Ashcroft Transmissions (http://www.ashcroft-transmissions.co.uk/part_79.html)

http://www.ashcroft-transmissions.co.uk/upload/large_44L.jpg

[long stroke]

We replaced the lt77 with a r380 in our 200tdi disco,not hard at all aslong as you have the r380 bellhousing.

[up2nogood]

I was going to do the LT77 to R380 conversion to a V8, but the other half needs to drive it and likes autos.

Have it for sale, but it's not the diesel one.

http://www.aulro.com/apc/showproduct.php?product=1952