Gearbox ??????

[pughster25]

Hi all

being on holiday for a week 250 miles away all fine TD5 towing well, on the way home just put diesel in to get me the rest of the way, pulling off no problem, just onto the motorway changing from 4th to 5th a big clang bang grind for a second and Ive got no drive what so ever, tried 4th and had drive so carried on in forth to next services 40 miles away as I had small children on board, just wanted to try to see if I had the lower gears before tackling the M5/M6 interchange at rush hour, gets to the services and I have no gears except 4th, take it the gearbox is whacked and needs a recon fitting, is this correct? also is this a hard task on a TD5?? any special tools required? and also is there any picks of anyone doing this before , have searched and found nothing

Also the fuse for the horn keeps blowing any ideas??

cheers

pughster25

[lawson]

Hi there
It does sound like ur gearbox is F****d 4th gear is a straight through gear on the main shaft the most likely cause is a stripped input shaft because all geare except 4th go in on the mainshaft and go straight onto the lay shaft. it could also be a stripped layshaft. The best way to check is to drain the oil and look for chunks of metal, also look at the colour of the oil it will probably look very metal coloured. If it is the gearbox u can repair them but it is cheaper and easier to get a recon one the best place is probably ashcroft transmissions all prices will be on there web site urs is an R380 box. As for fitting it is not an easy job to do on the ground although no special tools are rqd.
As for the horn does the fuse blow as soon as u put it in or when u press the horn. Lawson:o

[pughster25]

Hi Lawson

cheers for the quick reply,
You say changing the gearbox is not an easy job, I was fitter by trade have worked on Perkins diesels before also, (though they were the generator set diesels and 100x bigger than the TD5) and have always had motorcycle engines and gearboxes in bits since my childhood, is it possible with 2 men to do the job with relative ease,

is there any how to's about ?


not really sure when the fuse blows, replaced fuse used the horn no problem, came to use the cruise control and the steering controls wont work, replaced fuse and they worked again for a few days, it must be something else on the circuit that we dont use often that cause the blown fuse, just thought I would post here to see if it was a common problem before I investigate it further

cheers

pughster25:p

[lawson]

It sounds like u know what ur doing it isnt a bad job just difficult to lift out and in, if you use a trolley jack it will be easier to lift in and out 2 men could probably do it. Once u are sure it is the gearbox at fault you can get parts for them but you do need special tools to replace parts inside the box, if you get a recon one i dont see why you couldnt replace it yourself. Your best bet for a repair manual would be Ebay or poss a haynes from halfords should have a procedure for replacing a gearbox. it isnt a bad job but there is quite a bit of stuff to take off to get it out. As for your horn problem im not sure it could be a wire rubbing against something and just blowing now and again i would put a fuse in and try different things one after another and see what makes it blow again then you have a rough idea what your looking for. Hope this helps. Lawson:D

[pughster25]

will the rave disc have the details to replace a gearbox?

Everywhere wants £450-£500 labour, and the box is £450, if I can do it with my brother over a weekend I would love to save the cash (That I dont have:rolleyes:)

Do you know of any guides on the internet forums?

cheers

pughster25

[lawson]

Have u got a rave disk because i work in a dealer and before we had the online manuals that is what we used but i have never used a rave disk myself but if it is a disco 2 disk it should have it on. There are other people who might know better than me on here. You and ur brother can do it the hardest part it getting it back in bacause you have to get the input shaft into the clutch an sometimes it takes a bit of wiggeling to get it on. If you are feeling strong and dont mind lieing on your back for hours you should do it as it will be more satisfying knowing you fixed it yourself. How many miles has your car done, as if you do it yourself i would remove the clutch while the box is out its only held on by 5-6 nuts. But remember the plate only goes in one way so when you pull the cover off take the plate with it and dont turn it over. You are looking at how close the lining is to the rivets on the plate (you probably already know that). Also when you put it back on make sure it is alligned correctly. Hope this helps. Lawson:p

[pughster25]

I have a rave disc but have only had a quick look at it, when you say the input shaft you mean the shaft from the gear box front that goes into the clutch, the car has only done 62,000 full history, will be replacing the clutch whilst box is off, I will make a wooden shalf to align the clutch to take the input shaft of the gearbox

cheers

pughster25

[lawson]

Hope you find what u need on the disk if not someone will know where to find it in a manual. Yes the input shaft is where the drive goes from the clutch into the box. A wooden shaft will do its just so when you put the box back in the real shaft goes in correctly. PS when refiting the box make sure its in gear so you can turn it to line up the splines on the shaft. Lawson Best of luck:D

[pughster25]

does anyone know the diameter of the input shaft so I can pre-fabricate a shalf prior to fitting new gearbox to save time?


cheers
Pughster25

[JonCooper]

I've always used a 1/2" extension bar for clutch alignment (twice this week! (cos I let the thrust bearing slip off :rolleyes:))

you could always use the input shaft from the old one?

[lawson]

Dont know the size of that exactly soz mate.

[pughster25]

Hi Guys

thanks for the replies

I have found a INdependant LR specialist called Landy Ltd in Wrexham, that can do the work for a VERY:D competitive price, Has anyone had any dealings with them??

cheers

Pughster25

[JonCooper]

I measured the shaft on a gear box from discovery 1 today ~

the diameter of the shaft is 0.875inches or 22.8mm

the diameter where the splines are is 0.993inches or 5.25mm

dunno if that helps, it's not from a TD5

[pughster25]

Hi Guys

thanks for the replies

I have found a INdependant LR specialist called Landy Ltd in Wrexham, that can do the work for a VERY:D competitive price, Has anyone had any dealings with them??

cheers

Pughster25

Landy Ltd will fit the recon box and clutch for £250 if purchased from them, Their boxes are around the same price as everyone elses, has anyone had any dealings are they any good?

[lawson]

As im from up north i have never heard of them but for that price you cant go wrong if you hav any probs after getting the car back just take it back. You should be ok.:D Lawson