Thread: Manual gearbox assessment (how long have I got?!)

G’day everyone,

Lots of the gearbox threads seem to be about diagnosing auto issues but mine is a manual so I’m making a fresh start, please direct me if I’ve missed a good post that will cover this.

We’re currently planning to do a lap in a years time, first up has been deciding if the disco is up for it. It’s a 2003 pre-facelift TD5 with 280k and many of the big ticket items done (clutch, radiator, fuel pump, abs modulator, steering components) and the engine feels good, so on that front happy to have a crack. But unknown is gearbox. Its been pretty notchy since we purchased and is especially difficult in winter cold starts. Had gb oil changed which was better for a few thousand k’s and then back to the same. Mechanic noted filings indicating bearing wear.

It’s not an issue driving with it once it’s warm and if you know the right lines to take changing gears, but it’s hard for me to know how much more we’ll get out of it and whether it will bust in the middle of nowhere. Mechanic and brother in law aren’t too fazed but they aren’t the ones who will be stuck in tenant creek for a month! Paying 5K for a peace of mind recon/replace isn’t really an option.

So I’m wondering:
- Is there a way to make an educated assessment based on feel while driving? I’ve got no baseline to know what to expect.
- It’s bearings most likely, so confirming the only options are recon or replace?
- What’s a failure look like in this scenario, am I stuck where it goes or is it likely to give me signs that’s it’s about to fail so I can get to a town pronto? Can I limp once it goes in a single gear or is that risking more damage?
- How crazy is the idea of buying a second hand gearbox, crating it up and having it ready to courier to me?

The other thing I’m planning to do is replace transfer case with a used from a 2a and put the CDL in, I’m in the gap year. Not sure if that changes anything.

Appreciate your help on what no doubt is a very subjective diagnosis.

Cheers!

The shift problem sounds like an oil issue my r380 made a grinding noise before it died cost was about $6k fitted with a new clutch and fly wheel the shift pattern can be greatly improved fitting a slick shift kit cost about $160.00 from England if I was to redo my box I would fit heavy duty bearings hope this helps. If your car is pre face lift then it's an 02 model as they were face lifted early to mid 02 and 03 models came out with cdl fitted some 02 models have no cdl fitted to the nose cone of the transfer case.