Thread: R380 rebuild after 5th gear failure

Agreed. Don't want to have to machine housings!
Regards
Robbo

Originally Posted by pjh4159

Hello from another td5 R380 defender owner that also tows a large caravan and I was very concerned about the continual strain on 5th gear when towing.
As the defender has lower gearing than the Disco it is very tiresome to continually drive in forth gear to save 5th gear strain and I am sure other road users would not be happy either.
The solution for me was to fit a roverdrive to the R380 then drive in forth gear with roverdrive selected.
I have found this to be a great combination as the gearbox temps are reduced significantly and the additional oil volume in the transfer case dissipates any extra oil temp in the transfer case.
Although this is an expensive option it hopefully will avoid gearbox repairs in the future.
I hope this helps other Landrover travellers go further without gearbox problems.

Don't think the O/D will fit in a Disco. Was BD in Sydney toying with the idea?
Regards
Robbo

Over the weekend I managed to complete the gearbox rebuild.

The end float for the main shaft and layshaft measured up OK so I went ahead and completed the final assembly of the main housing. It took four attempts before I was convinced that everything was meshed and seated correctly. The selector shaft is what makes it challenging to assembly but I got it in the end.



Centre plate on next. Nothing difficult here.



Then assemble reverse and the all new 5th gear. Again everything went together nicely.



Rear housing back on and the job is done.



I was constantly checking and rechecking but it was nice to get to this stage and confidently select all gears.

Today I reinstalled the gearbox and transfer case. Everything is working perfectly so far. No unusual noises and the gearbox selects gears beautifully. The new syncros and selector bushes give it a very nice feel.

So fingers crossed, it should be good for another 250 thousand kilometers.

Originally Posted by uninformed

Hi Dave,

what year were the last R380's made/installed from LR? The reason I ask is that Im guessing the only reason RHP is no longer making them is because LR have said they dont want them anymore.....I would have thought there be some legal obligation for LR to supply parts to service a product for "x" amount of years after last sale.....

here in Oz I think its 7 years?

Last current production in 2006, LR may still have them but not at a realistic price,

Originally Posted by robbotd5

Agreed. Don't want to have to machine housings!
Regards
Robbo

If we do we can put a bigger one in but this won't help the DIY rebuilders,

Dave

Hope I'm driving a D4 by the time it dies!
Regards
Robbo

Anyone have the little sucker (bearing) handy to mic up please ?

Originally Posted by awabbit6

Centre plate on next. Nothing difficult here.



Then assemble reverse and the all new 5th gear. Again everything went together nicely.

Daddo 1200 in the background ?