110 Gearbox noise in 5th

[Mikelsgt]

I have a 1998 110 TDI that has developed a loud rythmic noise in 5th gear.

We were about 200K from home and it got back OK in 4th gear. All other gears seem OK. It has only done about 110,000 although a lot of this is towing.

I know this is all a bit vauge but is there a known issue with this gearbox?

Mike

[stuart]

Afternoon,

The R380 Gearbox has always had a problem with 5th Gear...it's never a good idea with these boxes to Tow in 5th...on the flat with no load is ok but soon as it's loaded it normally just spits the gear off...i would recommed putting a bearing/Synchro kit and Putting new gear in it...Should be all good then...

Stu



I have a 1998 110 TDI that has developed a loud rythmic noise in 5th gear.

We were about 200K from home and it got back OK in 4th gear. All other gears seem OK. It has only done about 110,000 although a lot of this is towing.

I know this is all a bit vauge but is there a known issue with this gearbox?

Mike

[Mikelsgt]

Thanks Stu,

Looking at other posts (like for the TD5) it seems the 5th gear is at the back of some boxes and may be able to be replaced without removing the box. Anyone know if this is the case with mine?

Mike

[justinc]

Mike, just did one, can be done in the vehicle. It is only possible with the R380, not LT77, and is quite easy actually. As Stuart says, A few bearings and possibly 5th gear if it is damaged but you MAY have caught it in time:)

JC

[djhampson]

I've moved this thread into the 90 110 130 Defender County section as you may get a response from people who don't venture into General.

[abaddonxi]

I've moved this thread into the 90 110 130 Defender County section as you may get a response from people who don't venture into General.

OT

Name names. Who doesn't venture into General Chat?:p

Simon

[Mikelsgt]

If there is a weakness with 5th gear is there any alternative to just replacing with original parts?

[slug_burner]

strongest gear in the box is usually 1:1 straight through the box for R380 it is 4th. I think in the case of 5th it is a size thing.
My experience was that the input shaft and the gear where it mates to the lay gear destroyed each other. Areas of concern are the lubricant, ATF has been replaced by MTF94 as the recommended lubricant. Change it every 20k.

The strongest option for an OD is an external OD attached via the TC PTO cover. Rocky Mountain ODs appear to be one of the stronger known options.

[PAT303]

There is no vehicle maker that recommends towing in fifth or in O/D if its an auto.It is very common in LC's and Patrols as they are the most common vehicle the grey nomads use as they try to save money.Saying that the 75 series box's are very weak in fifth,the box would fail before the original tyres wore out,seen it many many times. Pat

[Mikelsgt]

And the verdit was ....

After delays for Xmas and then January holidays the beast is finally fixed!

It had stripped a number of teeth off 5th gear.

Gear and synchros replaced and seems fine.

I tow a Tvan (all up about 1200kg loaded) is advise never to tow in 5th or only if flat under no real load?

[Perusalstein]

Mike, just did one, can be done in the vehicle. It is only possible with the R380, not LT77, and is quite easy actually. As Stuart says, A few bearings and possibly 5th gear if it is damaged but you MAY have caught it in time:)

JC

Justin am I understanding correctly.. that it's possible the R380's 5th gear bearings could be changed while the gearbox is still in the car?
And ? third gear synchro?

-Brouss

[justinc]

Only the 5th gear components unfortunately. Anything else requires a total removal and strip down.

JC

[TeamFA]

And the verdit was ....

After delays for Xmas and then January holidays the beast is finally fixed!

It had stripped a number of teeth off 5th gear.

Gear and synchros replaced and seems fine.

I tow a Tvan (all up about 1200kg loaded) is advise never to tow in 5th or only if flat under no real load?

Well done... good that only 5th gear needed replacing... our R380 sheared the layshaft - thought luckily didn't destroy the oil pump at the same time.

I drive differently now - I would definitely suggest 5th gear when towing ONLY when level driving, and minimal acceleration, if any. If you have a look around at pics of the layshaft in the R380 (my rebuild thread has some, I think), you'll see how weak the layshaft is where it exits the gearbox into the extension housing, which is where both 5th and reverse gears reside.

I'm also wary of applying too much power through reverse gear as well, after a look at the gearbox design.