My gearbox is fixed

**Frenchie** · 26th September 2007, 07:32 AM

For those of you that remember, before I went off on hols I was suffering from a noisy 5th gear. I have an aftermarket warranty and they made me take it to a gearbox specialist (plug here Gearboxes WA they are very good) rather than the LR specialist that I wanted, argued till I was blue in the face but they wouldn't listen.

Anyhow, after stripping the box and coming up with a quote around $3200 (I am covered for $4k

) they jumped up and down and told him to look for a second hand box

. Good job I was away or I would have told them to stick it. He couldn't find one anyway and the only service kit available was the whole bucket and dice.

So I got, at great expense to the warranty company, a new 5th gear, all new bearings, synchros and seals for the whole box. Had the clutch changed while the box was out as well.

Aparrently they were complaining to him about how much I had cost them. The bill so far - one ABS wheel sensor, $800, fuel pump $1000, head $500 (I had to pay the rest) and gear box $3200. The warranty cost me $1000 so I'm well ahead.

Here's the damage:

**mns488** · 26th September 2007, 07:34 AM

well done.

you were due for some good luck

hope it doesn't let you down

**George130** · 26th September 2007, 08:11 AM

Yay. A win!

**Dunnie** · 26th September 2007, 08:40 AM

About time the ba----ds paid up. They have always wriggled out of paying for ANYTHING on our vehicles. Well done.

**spudboy** · 26th September 2007, 08:44 AM

Good work. I have had a few warranties but never managed to get a claim paid. There is always some fine print that excludes your particular problem!

BTW - What vehicle? With an ABS sensor and a $1000 fuel pump I am guessing a Disco TD5.....

**Frenchie** · 26th September 2007, 12:18 PM

Originally Posted by spudboy

Good work. I have had a few warranties but never managed to get a claim paid. There is always some fine print that excludes your particular problem!

BTW - What vehicle? With an ABS sensor and a $1000 fuel pump I am guessing a Disco TD5.....

Close - a Defender Td5!

**Redback** · 26th September 2007, 01:40 PM

Any clue as to what caused it, i've seen the shaft fail in the Nissan and Cruiser but never seen the cog/gear fail.

Actually your the first R380/LT230 i've heard of with 5th gear failing

Baz.

**Frenchie** · 26th September 2007, 06:11 PM

Originally Posted by Redback

Any clue as to what caused it, i've seen the shaft fail in the Nissan and Cruiser but never seen the cog/gear fail.

Actually your the first R380/LT230 i've heard of with 5th gear failing

Baz.

The advice I got from Rovertech is that at some stage LR changed the 5th gear from a bush to a needle roller bearing which wears out much more quickly. (Thanks Land Rover!)

I had bearing noise for a while before the real bad noises started. Maybe with the bearing shot the gear was vibrating or something causing the tooth damage? Dunno.

**Blknight.aus** · 26th September 2007, 06:20 PM

thats certainly feasable. but with the correct grade lube the needle rollers should outlast the bushes..... at least thats the theory. IF it wernt so no-one would have bothered inventing the needle roller youd just have the bush type bearing.

**Bush65** · 26th September 2007, 07:04 PM

That failure looks typical of what occurs when the bearings are worn.

The wear pattern and teeth broken on one side indicate misalignment resulting from worn bearings.

The load capacity of gears is very dependent on the precision of manufacture and alignment. The tolerances for modern high performance gears are extremely small. Bearing wear blows all of that out the window.

Those pics also show rovers trend to weaker gears, by using smaller teeth and lower pressure angles. My best guess is they have done so as an easier/cheaper way to reduce noise.

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