gearbox dead - 200tdi '93 110

**gmeddy** · 12th July 2011, 10:34 AM

I had no indications that there was a problem with the GB.
I gave it good fresh oil about 20k ago and recently checked it was still at a good level.
No noises, no problems, then all of a sudden, just as I was pulling out of a parking spot... bang. No drive.
No drive in any gears, tried the transfer case, high, low, lock etc etc...
nothing.

towed it home with my '83 Toyota Tercel 1400cc wagon and took the inspection plate off the transfer box, no signs of wear, no chunks in the oil.
rocked the vehicle back and forward with the Transfer box engaged and it was good, the axels were turned by it, but then engaged the GB and it didn't engage the motor.
just made a sloppy noise inside the GB.

I have found out from reading on Ashcroft Transmission's site, and emailing Dave, that it is not an LT77S box like the book says it should be with a 200tdi, but it is actually an R380 "Shorty" box.

I will have to find a way of removing the box myself and diagnosing the problem, and order the parts, then find someone good to fit them for me.

any thoughts on my best options?

Thanks

**weeds** · 12th July 2011, 10:40 AM

just making sure you did enage centre diff lock as this will rule out something simple like a drive flange or cv........

**bee utey** · 12th July 2011, 10:46 AM

Isn't the output shaft of the gearbox prone to wearing out the spline? Take the transfer box off first, look at the output shaft. The gearbox is then lighter to get out.

**rainman** · 12th July 2011, 10:53 AM

You beat me to it bee utey!

When you say you pulled the inspection plate off, was it the big rectangular one on the bottom of the transfer case, or the round PTO one at the top on the back? If you pull the PTO one off you'll be able to see whether you've stripped the gearbox output shaft. Early R380/LT230 setups didn't lubricate the splines properly, but I would have thought all would have been fixed or replaced with the drilled out gear by now.

**Psimpson7** · 12th July 2011, 10:57 AM

agree with Bee Utey,

Likely to be the splines on the input gear in the transfer case.

You can probably get it out without removing the transer or gear box.

Undo the back plate on the back of the transfer case and pull the input gear with bearings out. You will then be able to have a look at the splines, and fit a new gear if required.

As far as I can tell it doesnt need much setting up.

**rainman** · 12th July 2011, 11:03 AM

Originally Posted by Psimpson7

agree with Bee Utey,

Likely to be the splines on the input gear in the transfer case.

Unfortunately when mine went about ten years ago it was the output shaft splines, ie gearbox rebuild.

**gmeddy** · 12th July 2011, 02:55 PM

wow, thanks for all the fast replies!
thats great news that it could be so simple!
yeah i only looked into the rectangular plate, not the circular one.

I have just got out from under the car, i pulled off both prop shafts and the hand brake drum and took off both the panel under the centre cubby box and the cover around the gear shifters in preparation for removal of gearbox(s) - but if i may not need to do that in the end that is the best news i've had all decade!

oh and yeah, i did try it in "diff lock" and still had no drive.

- i never knew that you can change from lock and unlocked without first shifting up into neutral, i just figured that one out today fiddling with the stick. ;-)

**gmeddy** · 12th July 2011, 03:26 PM

Psimpson7, are there any special tools/pullers to use to get the input gear with bearings to come out and to refit?
I will start on this job immediately.

**rainman** · 12th July 2011, 03:37 PM

I don't think so gmeddy (but it has been a while for me). As in Pete's pictures, remove the six bolts and cover, and then ease off the round retaining plate which has the outer bearing race in the front face. Then the gear complete with bearings slides out, off the gearbox output shaft. If the splines are stripped it might help to gently rock the vehicle with the transfer case in either range. Be careful not to dent or score the flat surfaces of the cover and plate if you have to use a screwdriver.