Thread: R380 rebuild after 5th gear failure

How many Km have these boxes done?
Interestingly the one I just did had done 90 odd thousand ks
but my original has 200000 on it and doesn't seem to have any issues

i'm wondering duane if there isn't some poor bearings about, or maybe poor factory assembly, out of line centre plate bores ? etc? as i have seen the same, some at 90k, no towing at all, others at 400,000km, all highway and some towing still no problems except worn output splines....

makes you wonder

i just fix 'em and send them back out

jc

Originally Posted by djam1

How many Km have these boxes done?
Interestingly the one I just did had done 90 odd thousand ks
but my original has 200000 on it and doesn't seem to have any issues

Mine had done 156,000km.

I said earlier that I pulled the gearbox down as soon as the noise developed. However, it would have been more accurate to say, "as soon as I noticed the noise".

As this thread explains, it needed a particular set of circumstances for me to notice the noise. R380 5th gear
So the bearing was fairly obviously deteriorating for some time before I noticed the noise.

I don't know if the vehicle had done much towing in the 112,000km before I bought it. I haven't towed anything.

Originally Posted by djam1

How many Km have these boxes done?
Interestingly the one I just did had done 90 odd thousand ks
but my original has 200000 on it and doesn't seem to have any issues

Mine is at just over 260000 km.

154,000km - 1999 Dual cab 130

The PO had done some towing of a dual axle trailer, camping but no 'off-road'.... undercarriage is mint.

Originally Posted by vnx205

Was there a bit of a noise in 5th and reverse that you either ignored or hoped would go away?

The reason I ask is that as soon as mine developed a noise, I pulled it down and found that bearing looked like this.

Here's a photo of my bearing for comparison,



Not quite as bad as yours.
The thing that I noticed that was interesting was the difference in width of the wear across the bearing race. Mine is wider. It would indicate slight differences in the width of the rollers.

The similarity of the damage in this photo to mine is amazing. It's identical!

Have you got yours back together yet? How much did you replace?

Originally Posted by Fubar

I've recently had exactly the same failure with my R380 as the OP's. Unloaded changing from 4th to 5th with part throttle (no coooler, MTF-94 & and mild chip by PO)



I've gone through the box and t/case like a dose of salts and refreshed everything even slightly suspect. It can be a long process......I'm itching to get my 130 back into action.

Jas

I placed my order with Ashcrofts today. Here's the parts list:

• R380 rebuild kit - £190
• 5th Layshaft - £42
• 5th Mainshaft - £38
• Discovery selector bush (FTC2203) - £4

The kit includes all bearings, seals, baulk rings etc. Quite a good price for what is in it.

My plan for today was cleaning casings etc. All was going well until I tried removing the oil pump. I broke 3 T20 torx bits! The three screws with the T25 head that hold the pump together are all loose but I can't budge the screws that retain the pump. I'll go and buy a couple of better quality T20 bits tomorrow and have another go at it. I sent Dave an email to ask how he gets them out when they won't move. He has had to drill out the heads to get them off. This is something that I had considered but I am trying to avoid it. (The rebuild kit comes with new screws ...)