4BD1T MSA5G Range Rover Classic Outcast Adaptor

**workingonit** · 12th January 2015, 11:27 PM

Sorry Vern, I know your tired, but input gear, not intermediate

or is it my 'bad' somewhere in the posts?

SteveG, I bought my input gear for the 1.2 box in my Disco Tdi300 auto. I did wonder if it was a universal fit for other ratios. I've not played with gearbox ratios before. So to change ratios how many of the gears are involved ie just the input, input/intermediate, or more? I guess I should check Ashcrofts site.

My experience to date, dealing with early and late Disco 1 models, is the long spline came out in later Tdi300 Discos, cross drilled for lubrication, to help reduce failures. What LRover didn't do in later gears was machine the nub to make dog teeth to accommodate hydraulic pumps or other devices. The older short version did have dog teeth. My aftermarket long spline does have the machined dog teeth.

I assume ratios other than 1.2 did also suffer the lack of lube issue on the input gear/shaft. But LRover did not do the long spline crossed drilled replacement like they did in the Disco?

**Vern** · 13th January 2015, 09:32 AM

Yes tired and p'd off. I meant input gear.
I'd measure my adapter shaft but have no measuring device. It does however come upto the shoulder on a bottle of jameson

**workingonit** · 13th January 2015, 11:32 AM

...it's driven you to drink then?

I assume you are still able access a Sheldon shaft, on loan.

What has happened to you has me worried about the Outcast shaft - they said they got to examine Sheldon's shafts and in their view made some improvements.

I'm pondering some issues and will have some questions for bee utey after his interesting last post on the other thread, basically indicating even Ancient Mariners set up may present problems.

I'm a long way off testing the Outcast unit. My certified welder has just emerged from his holiday south, so I'm still at the stage of attaching engine mounts and bracing plates. In the mean while I've been sand blasting suspension parts and painting them.

Again, a pity whats happened. Was looking forward to an upbeat report when you got back.

**Vern** · 13th January 2015, 06:47 PM

Yeah have a loaner shaft, picked it up today.
All I can say is I'm amazed how easily this snapped, i'd be very concerned if i was doing any slightly remote travel.
CWhen i get home, the whole engine/trans combo is coming out, i need to fix this week link properly

**loanrangie** · 13th January 2015, 08:03 PM

So your holiday is stuffed too :thumbdown:

Sent from my GT-I9300 using AULRO mobile app

**isuzurover** · 13th January 2015, 09:47 PM

Originally Posted by Vern

Yeah have a loaner shaft, picked it up today.
All I can say is I'm amazed how easily this snapped, i'd be very concerned if i was doing any slightly remote travel.
CWhen i get home, the whole engine/trans combo is coming out, i need to fix this week link properly

The design of the shaft looks OK. Sheldon is a Mech. Eng. (AFAIK) after all. He didn't make the shaft out of balance at least... (like someone else we know)

The radius at the transition could have been greater, but I suspect misalignment, heat treating, or the material.

**Vern** · 13th January 2015, 10:00 PM

Originally Posted by isuzurover

The design of the shaft looks OK. Sheldon is a Mech. Eng. AFAIK after all. He didn't make the shaft out of balance at least...

The radius at the transition could have been greater, but I suspect misalignment, heat treating, or the material.

Thats true, but none of these are my fault or problem, but now it has become my problem. Very dissapointed.
Do you know how hard it is to try remove an lt230 with limited tools, lying in the sand, by yourself? It really gets you down.
Now if i could have just removed the input gear and swapped out the snapped axle, i'd be in a better mood right now.
Trust me, i am very grateful for all the hard work sheldon has done, and am happy with the kit, i just want him to know what has happened so he can see if there is a way that this won't happen again, but i just can't seem to get onto him at the moment.
Plus i am on holiday with my family, thats the worst bit.

But in the long run it will be new and improved😊

**workingonit** · 13th January 2015, 10:29 PM

Ok Isuzuurover, lets see how critical the chunk out of the Outcast adapter really is...Damien, you wanna free Outcast shaft...

Gotta stop taking the micky

Anyway, off to annoy the people on the 'other thread' (you guys basically

)

**isuzurover** · 13th January 2015, 10:38 PM

Originally Posted by Vern

Thats true, but none of these are my fault or problem, but now it has become my problem. Very dissapointed.
Do you know how hard it is to try remove an lt230 with limited tools, lying in the sand, by yourself? It really gets you down.
Now if i could have just removed the input gear and swapped out the snapped axle, i'd be in a better mood right now.
Trust me, i am very grateful for all the hard work sheldon has done, and am happy with the kit, i just want him to know what has happened so he can see if there is a way that this won't happen again, but i just can't seem to get onto him at the moment.
Plus i am on holiday with my family, thats the worst bit.

But in the long run it will be new and improved��

Not having a go at you Damien. Wouldn't want to be in your situation. I hate working on vehicles "in the field" (done plenty of it in my time, but not as serious as removing t-cases...).

People seem to be crawling out of the woodwork claiming the design was flawed all along - it is in their direction that my comments are aimed.

**Vern** · 14th January 2015, 01:25 AM

All good Ben, i know your not, i totally agree with you.

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