Thread: Manual Gearbox Kaput! - TD5 D2a 2003

Bottom Line Up Front - I need some advice and guidance on a failed R380 gearbox in my D2a (2003) - essentially, I'm assessing options ranging from full Ashcrofts replacement down to cut my losses and break her up for parts...

I've finally signed myself back up after a couple of years off of the site (2 new kids and a change of career) where I once was a regular. It's good to be back and see things are still as good as ever.

Problem though - as the title suggests, I'm in need of some assistance to navigate the challenges of a manual gearbox failure in my beloved D2a TD5.

I'm in SA and the car is currently with a (trusted) mechanic who was checking out some irregularities with the 'box during a service (and fixing the fuel pressure reg leak). The mechanic rang me with "that tone" in his voice to report the bad news as he dropped the oil out of the box - which included water and some metallic components that shoudn't be loose...

Some background - I bought the car stock and immaculate at 80k km from a bloke who was quite honest about the fact that due to his bung knee he thought that he'd done some damage to either the gear box or prematurely aged the clutch. I did quite a few of the usual modifications to the vehicle and the odometer now reads 195,000 km. Has been a brilliant daily drive and done a moderate amount of offroading, touring and towing. Never really had any great trouble with it.

My intent is to get the car back on the road and keep it well into the future if I can. Decision will be a balance of cost, risk and difficulty (the stuff around factor). I've got a backup car so I'm in no rush.

So - I'm currently evaluating my options which are:

1. Import a complete box (plus all of the extras for the clutch as well) from Ashcrofts. My mech fits it.Car good to go. Make the busted box into an umbrella stand or something...
2. Find someone in Australia (SA if possible) who can do a rebuild of the current box using the Ashcroft rebuild kit which I'll get sent out from the UK.
3. Get a rebuilt box and do the swap-out (old for new) here in Australia.
4. Just put a second-hand box in from a wrecked vehicle and then have a crack at doing the gearbox rebuild myself with a kit from Ashcroft.
5. Don't bother, sell for parts and buy another vehicle.

Righto - I'll open it up to the floor. I'd sincerely appreciate some guidance here. I'd love to hear from anyone who's been through the process and has some numbers to throw at me. I haven't been to visit her at the mechanic's yet since the nasty diagnosis - will be doing so tomorrow arvo. Mech wants to investigate the Transfer Case as well as it's leaking - I'll update tomorrow once I've visitied the "hospital".

I'd especially love to hear from anyone who'd be in a position to maybe mentor me through either the process of getting a kit/box from overseas but especially anyone who'd be able to take me under their wing to attempt a rebuild with a kit here in SA (I can come to you and will pay.) I'm thinking anyone retired or who has time on their hands to work with me on the rebuild.

Look forward to the conversation that will no doubt rise up out of this.

Thanks in advance - Adam

In all honesty, if ur after a reliable fix go to Peter at PCB. They're definitely not a budget repairer, but you will get a super reliable fix by an honest professional. In other words, if you plan on taking ur Landy somewhere remote, take it to Peter 1st.

I'm not affiliated with PCB at all.