D1 300tdi R380 Gearbox Removal

[Phillip]

Hi All,
The gearbox in my D1 has rattle in it when in nuetral and cluthch out. I think it maybe the front bearing. Which is the best way to remove the gearbox? With the engine in or out? I am sure many of you have done this job.

[B92 8NW]

My gearbox rattles on idle, in neutral, with the clutch up This is very common on both the 200 and the 300 TDi engined vehicles. The clutch friction plate has a ring of springs, which are there to soften the knock of the diesel engine to stop it being transmitted to the driveline. Often especially with a new clutch these springs are quite tight and a lot of the engine knock goes through to the gearbox and makes the gears "chatter" together when the box is in neutral and the clutch up, it goes when the clutch is depressed. This can sound quite bad and does vary from car to car but is not detrimental to the life of the gearbox and we view it as an undesirable characteristic of the LT 77 and R 380 as opposed to a fault with either the gearbox or the clutch.



My 200 TDI w LT77 did it to

[awabbit6]

Mine does it too. I find that if I depress the clutch and then release it again, it is instantly quiet. This confirms the above reply - normal gear rattle that is more noticable due to the normal diesel vibration.

[Scouse]

I'm sure I read something from LR about this & it was loose layshaft bearing preloads. Either way, it's a box out job.

Leave the motor in. Unless you have a big transmission jack, it's be easier to drop the transfer case first, then remove the gearbox.

**EDIT: I've just checked. It was something I read but it was 15 years ago & applied to the LT77 gearbox.

[ATH]

Mines got it with a new H/D clutch but had Kevin at RoverTech have a listen and he said it's normal.
Put my foot on the clutch and it stops. Sounds worse when in the carport and the noise reflects off the walls.
So I'm leaving it alone.
Alan.

[Taz]

Leave the engine in if you have a transmission jack.

One thing - Tdi's have a design fault on the throwout bearing yoke arm. It bends and then breaks leaving you without a clutch. Apart from the noise, if the clutch starts to feel a bit unusual, becareful as it may be just about to fail.

If not, it would be very wise to replace the arm when ever you drop the gearbox. They only cost around $50.

[Blknight.aus]

you can do it either way depending on how your equipped.
\
IF you're skint on gear but strong on big mates by seperating the tcase first the main transmission can be lifted down and out by 2 blokes some wood chocks and one of those cheap 2 t supercheap trolly jacks.