Thread: TeamFA's Gearbox Repair '02 Defender R380

Originally Posted by Davo

BUY IT! Because you'll really, really need it one day and then you won't care what it cost you. Trust me, I've learned all about this over the years. I must have two or three dozen tools I've bought or made and only use twice a decade, but when you need them, you really do need them.

Davo, I really, really hear you... but this is one time I can't justify the expense for such a little-used (hopefully) item. I also have a workshop with more tools bought for a single purpose, then rarely (if ever) used again, that you can shake a left-handed counter-oscillating carbon-fibre stick at.

Were times more fiscal, I should have another one to add to the collection...

Cheers!

Originally Posted by Blknight.aus

Yep, you can borrow mine, but I'm not home till the 20th.

Cheers Dave, I'm only going to be ordering the parts on Wednesday, so it's unlikely I'll get to that stage by the 20th, so I may take you up on your offer... I'll PM you then if so.

Thanks.

Ordered the parts...!!!

... big plastic box of parts on my doorstep yesterday afternoon... woo hoo! This weekend the fun begins...

Good job! Take lots of photos and use little words when explaining.

I'll be following your 'Voyage Of Discovery err...Defender' closely.

Deano

Happy with my progress thus far. Started work on Saturday lunchtime, by tools-down last night I had a reassembled gearbox/extension housing attached to the bell housing, new clutch fitted, and clutch release lever cleaned, lubed, reassembled and fitted.


Box arrived.


Mainshaft in ready for bearing race and end-float check.


Test-fit centre plate.


Ready for assembly, prior to input shaft.


Centre plate on!

Lining up the selector for 5th/reverse stumped me for a bit - and whilst stuffing about I accidentally pulled the selector shaft out too much, which had the effect of locking the box in 4th... so I had to remove the centre plate and re-do the selector shaft.

This is how the 5th/reverse selector lines up. The manual has good instructions on how to set the selector shaft up inside the box, but lacking a bit on how to align it for assembly in the extension housing.


How I use my puller set pieces with the press to get some of the bearings and races on.

Overall, the process has been easier than I had imagined. Actually getting hands-on with the gearbox, disassembling and reassembling makes it clear how they actually work. This is my first look inside one, and I must admit that it has always been a bit of a "magic box" as to how it all happens in there.

The workshop manual is one of the best I've used - previously used Haynes manuals for the Harley Sportster and VN/VT Commodores, and a factory Buell manual for an M2 and the current XB12R. The Land Rover one is excellent.

Now comes all the boring bits of getting everything back together, before I can see if it all works. I can engage all gears by manually moving the selector shaft, so it's looking promising...