Thread: Adapting the R380 to 4bd1

Swaped over to the 300tdi tunnel today it has about 25mm of insulation on the under side and more room around it for vibration on cold start I found I had to use a cover plate of aluminum and riveted a flange onto it to cover the 200 tdi cut out see pic.Took it for a drive and it's much much quieter

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I skipped over this section pretty quickly but I thought I'd add a bit more about the actual gearbox conversion itself because k or l suffix 300tdi box are rare so if you want the strongest r380 this is what you do to get one using the defender td5 r380 first remove the collar from the output shaft .I used a bearing splitter around the collar coupled to a puller then remove the rear aluminium housing then the steel forward housing leaving the sandwich plate in the center from the pic from the manual remove 1 lay shaft bearing track the undo 2 32mm nut it's tite you'll need to make /buy the special tool to hold the gear then remove the tapered washer gear 5 gear 13 .you can then lift and tilt the lay shaft to remove the pinion shaft .once u have the pinion out and in the vise remove the bearing shell from inside the gear I used a prybar also remove the the main bearing I tapped it off with a sharp chisel . Ok now refit the bearings to the tdi pinion TUD102580 and refit the rest remember to restrake the nut fit the housings then the collar last I used a 35mm id pipe 250mm long a nut and m 12 thread rod that's it I think

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