My D1 manual transmission is a bit noisy and clunky...is this normal?

Find the filler plug and stick your finger in it, if it comes out wet...you have enough oil, if not it needs more!..

if you are going to change the oil, it's easy to get out as the drain plug is clearly at the bottom, putting it back in is a bit harder as it's all in the most awkward place, a fluid pump is the go for that, i got one for 20 odd bux at Repco, takes a while but is pretty easy, when oil starts to drip out the filler plug, you have enough.

Although i can't for the life of me remember what oil i put in...

Ray

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Originally Posted by Young Angus

Hmm how do I go about checking and changing my gearbox oil? Is it the same kind of thing as changing engine oil or are the bits much harder to get to?

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The filler plug is a flat plug that is a Torx 55 up on the drivers side of the box.
I would try and make sure you can undo it and not have had previous owners damaging the plug by using the wrong tool before you drop the oil out from the bottom plug.
I had this problem when I bought my Disco, I drained the oil and found I couldn't get the filler plug out. This will strand you.
Easy to fill with a pump. the TOM THUMB 1 Lt pumps do the job, but are slow. Just hook the pipe into the hole and pump, you will have to refill the pump a few times

And lovely oil down to the elbow. Stops the forearms rusting.
You can also use one of those "oil injectors" which look like a grease gun. (as I do) They are even better at oiling forarms.

Regards Philip A

My D1 gear box is a little noisey when changing gears but I try and treat her gently through the gears so she goes in smoothly otherwise it can be clunky.

That's basically what I've noticed...so long as I don't try and change gears like I'm in a little rice burner it doesn't clunk too much. I still wouldn't mind making sure all the right bits are in the right shape for my own piece of mind though.

The LT77 in our Disco is quite noisy and crotchety at the moment, but it's only become slightly worse over the last 5 years / 80,000km.

The main source of the noise in ours is the output shaft that Blknight mentioned. The shaft and the transfer gear were badly worn and I replaced the gear a couple of years ago to try to extend the life a bit. Essentially it creates about 5° rotation in the coupling between the gearbox and transfer when there should be none. Combined with diffs that are not new, a little wear in the drive flange on the front passenger side, and various worn parts and bearings in the transfer it makes a fair bit of drive line slack.

The trick I settled upon early was to shift with only just enough clutch pedal to interrupt drive to the gearbox for half a second or so. This way the lag in the drive line is being pulled taught, rather than allowing it to go slack and then be taken up abruptly. It's something you get used to and only really notice how slack things are when you go off road in slow rocky terrain or someone who doesn't know the car gets in to drive it.

The fixes? The output shaft on the gearbox can only be replaced with a complete rebuild if it's really worn (expensive) but if it's not too bad you can replace the transfer input gear only to buy some time. If it's really bad you will need to address it. Total loss of drive occurs when the splines let go so you never want to leave it that long.

This will show you the extent of my problem with ours.

http://members.optusnet.com.au/~mac.man/transfer_gear/index.html