ForumSage
As my 1998 R380 is at 330k with alot of that Towing 1.8t, and starting to get quite sticky changing gears, I figured it time to get another and rebuild it so I can change out before it dies and cost alot more.
I sourced one from a member here, and with some very helpful other members it was transported to the sunnycoast where I picked it up.
This box is from a 2006 Td5 110 ex UK. It came with a broken extension housing, that being one of the ears that bolts up to the T/case (probably the muppets installing it having dowels in both gearbox and t/case at that point!)
When I did my orders from Ashcrofts, I was told (by the odd serial number) that it was a factory rebuild (would have been done while still at the dealers)
As I got it:
Break in rear housing and nice work on oil pump sealing!
Non standard drain plug and nice amount of crap on it
ForumSage
Removing the rear extension housing revealed broken bearing cage(these are plastic and it may have been removing the housing that did it??) and the bearing track showing the usual signs of starting to fail ( I think this box only had 90k on it from new!)
ForumSage
Removing main shaft collar:
Part of my home made anti-rotation tool:
Removing bearing track from main shaft:
Parts removed from main shaft above the centre plate: (in order from left to right, rows bottom to top. Note last small gear is off the layshaft)
ForumSage
Next is pretty much remove the centre plate and you see this:
Note the two bearing tracks have shims!:
You remove the whole assembly as one(main, lay and selector shaft assemblies). This is the main shaft assembly with selector shaft and forks:
Another view:
ForumSage
SupporterThat must have been a bit noisy.
I could hear mine with this much wear.
1973 Series III LWB 1983 - 2006
1998 300 Tdi Defender Trayback 2006 - often fitted with a Trayon slide-on camper.
ForumSage
Pulling 4th gear and the TRB race above it off the main shaft: My puller didnt have enough reach so I made up some extension arms in flat bar (black looking things)
Everything pretty much just slides off the main shaft after that. Only the small TRB on the other end (that locates in the end of the imput shaft) needs pulling.
Pulling TRB from the layshaft:
Both ends of the Layshaft have similar size/looking TRB, but one is taller than the other!
ForumSage
Having removed the end plate from the main housing, I had to pull the TRB cup pressed in it. But I dont have a blind puller, press or jaw puller that would fit inside it. Even though there is a hole behind it for the seal, it does not allow enough room or direct line to drift it out.
I used the weld and let cool method. It shrinks the cup and they come out pretty darn easy.
ForumSage
my 110 is so noisy I dont know what is falling apartOriginally Posted by vnx205
That must have been a bit noisy.
I could hear mine with this much wear.
What condition are the gears in? Is there any wear on the tooth contact surfaces. The brass syncro rings look in very good condition compared to the 2 r380 boxes I've recently striped down.
ForumSage
There are signs of slight wear but they do look to be in pretty good condition (granted Im not a gear expert and not sure what to look for) I will give them a closer look once fully cleaned and being reinstalled on the main/layshafts.
Yes I figured the baulk rings would be ok given the mileage, and It was a toss up whether to change them out. I got various advice on what to replace and not. But what it came down to was I had to pretty much fully strip the box to change the input shaft to a Tdi type. So I figure just rebuild the lot while there.
I quite enjoy doing these bench type projects, but I doubt changing the boxes out/in the truck is going to be funSo I dont want to do that again before I have to.
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