Thread: Disco 1 manual gear box 5th gear

Contact Ashcrofts.

So there goes 5th gear...

I live over 1650k's to nearest capital city (Perth) ,..so may have to blunder along by pulling it out and seeing what is amiss.

Originally Posted by vbrab

I live over 1650k's to nearest capital city (Perth) ,..so may have to blunder along by pulling it out and seeing what is amiss.

Can be done with gearbox in vehicle. The only issue is how much metal has circulated through the transmission as it had been like that for a while... drop the oil and see how solver it is. It may be cheaper to buy a used unit and just fit that.

Jc

Originally Posted by justinc

Can be done with gearbox in vehicle. The only issue is how much metal has circulated through the transmission as it had been like that for a while... drop the oil and see how solver it is. It may be cheaper to buy a used unit and just fit that.

Jc

Not sure how you'd go removing the extension housing without removing from the vehicle.... To remove the main shaft oil seal collar a LOT of force is required. How do you do this in vehicle JC? Any puller I tried in the limited space of a D1 didn't work. No space for a bigger puller in a D1, but maybe there is in a Defender?

Either way, the biggest tip I can give is that you will need something epic to get that mainshaft collar off. (first thing you have to remove to remove extension housing with 5th gear in it).

Originally Posted by Judo

Not sure how you'd go removing the extension housing without removing from the vehicle.... To remove the main shaft oil seal collar a LOT of force is required. How do you do this in vehicle JC? Any puller I tried in the limited space of a D1 didn't work. No space for a bigger puller in a D1, but maybe there is in a Defender?

Either way, the biggest tip I can give is that you will need something epic to get that mainshaft collar off. (first thing you have to remove to remove extension housing with 5th gear in it).

I just use a generic long leg puller with a bearing plate on it. Easy peasy☺ to reinstall new one i heat it in boiling water and tap it on.

Justin, Last one I did my 15 tonne hydraulic puller and heat wouldn't budge it, then the 20 tonne press cowered at it, end up having to cut and split the mongrel, never again, Regards Frank.

Originally Posted by justinc

I just use a generic long leg puller with a bearing plate on it. Easy peasy☺ to reinstall new one i heat it in boiling water and tap it on.

Originally Posted by Tank

Justin, Last one I did my 15 tonne hydraulic puller and heat wouldn't budge it, then the 20 tonne press cowered at it, end up having to cut and split the mongrel, never again, Regards Frank.

😮😮 wow thats unusual. I must've done at least 20 to 30 of these over the years and used the same puller arrangement without incident. Sorry you had to go through that😯

Just done a mainshaft in a LT77 and 200Tdi out of a 1993 Disco and everything was super tight. Not sure if yours is this box or an R380.

This helped Rebuild of the LT77 Gearbox - Defender Forum - LR4x4 - The Land Rover Forum

Found Ashcrofts were very good. My plastic bush that the gear lever end goes into was very stiff and caused hard shifting when the box was hot. The oil pump shaft for the new metal type oil pump was 3mm too long and caused the box to go tight when tightening the extension housing.

Paul