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Thread: problems with LT77 gearbox after oil change

  1. 7th September 2004, 07:04 AM #1
    feraldisco's Avatar
    feraldisco
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    problems with LT77 gearbox after oil change

    Hi - I have a 93 Tdi200 Disco with 250K k on the clock. I was told that this was a lot for a LT77 gbox and also that Dexron ATF didn't provide sufficient lubrication. So I decided to replace existing fluid with fully synthetic Castrol Syntrans ($20/l !). I undid the extension case and gbox drain plugs and over 4 litres of fluid came out (it seems that whoever filled the gearbox previously had filled to the top filler plug (same side as drain plugs) level rather than the level plug (back of gearbox) level. I put in 2.7 l (as specs indicated) of Syntrans and all was good for first 50kays with very slick shifting action. Then a whine started in third and fifth. Can anyone explain what is going on here? Have I used the wrong fluid (even though it is recommended by Castrol for this model)? Have I not used enough fluid? I'm assuming the extension case is internally connected to the gearbox even though they are bolted to each other - i.e. they share the same fluid? If the plug at the back of the box is the correct level/filler plug, why is there a plug at the top of the gearbox on the same side as the drain plugs? Any urgent advice would be greatly appreciated - I don't want to drive any further until I have a solution and I hope I haven't done irreversible damage (maybe the gbox being full to the brim with ATF previously was hiding an existing whine???

    Thanks
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  2. 7th September 2004, 08:34 AM #2
    Defender200Tdi Guest
    Welcome to the forum feraldisco.

    The LT77 gearbox and LT230 transfer case fitted to your vehicle do in fact have separate oil capacities.

    The 5th gear extension drain plug (which has a plastic filter attached to it), is the drain for the gearbox only. There is a second drain plug for the gearbox which is located at the bottom and on the drivers side of the main section of the gearbox. This drain plug has a magnetic pin attched to it. Ordinarily both plugs are removed to fully drain the gearbox. Refilling the gearbox is done through the side level plug (a square head plug on the drivers side on the main gearbox case).

    The transfer case has separate drain and fill/level plugs. The fill/level plug is the one you have described on the rear face of the transfer case.

    As I said above, both boxes have their own separate oil capacities and fluid does not move between the two. The transfer case holds approx 2.3 litres and the gearbox holds about 2.7 litres.

    Hope that was of some help.


    Paul [img]style_emoticons/<#EMO_DIR#>/biggrin.gif[/img]
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  3. 7th September 2004, 08:52 AM #3
    Defender200Tdi Guest
    After reading my own reply...perhaps some pictures could do it better...






    That's better now isn't it?


    Paul [img]style_emoticons/<#EMO_DIR#>/biggrin.gif[/img]
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  4. 7th September 2004, 05:19 PM #4
    shaunp
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    Sounds to me like you have drained both boxes but only filled the transfer case. So drain the Syntrans out of the transfer case and put it in the 5 speed and fill the transfer case with EP 90 or if you want to put synth in it use Penrite 10 tenths 75/90, or Castrol SAF XA or syntrax. Next hope you need to hope you haven't hurt the LT77 the transfer case will fine.
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  5. 8th September 2004, 09:33 AM #5
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    feraldisco
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    yep, that's exactly what I've done, and yes, I do feel like a goose... Moved the Syntrans into gbox and put VMX80 into transfer case this morning. Whines from LT77 have disappeared (it hadn't been completely drained of fluid and I only drove about 50 kays before noticing subtle whine) and I just hope there is no underlying damage done. The interesting thing was that the gearshift was very slick even though there was virtually no fluid left - I always thought a sign of low fluid levels was difficult shift...
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  6. 8th September 2004, 05:16 PM #6
    shaunp
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    That's why it was slick oil stops syncros from working. Syncros are just a brake really
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  7. 1st December 2009, 09:24 AM #7
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    Over full LT77

    I was on the hunt yesterday for a whine in my gearbox, when I cracked the fill plug on the gearbox, fluid ran everywhere......... I think it may be over full?

    Is this a problem?, there is oil dripping off the box, Im assuming it's from the breather, as it is not that bad.... I have noticed my second gear syncro has gone... but if you watch the rev's and are gentle, tis all good, it has a constant whine under load, coasting in gear and nuetral no noise, it appear's only when holding at speed on the road.....I can live with it, but do I have to?

    Auto..... would it be an easier option to fit a ZF auto box to my S1 Disco?
    may well work out to be an easier option...

    Any thought's....................
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