HELP! 200tdi disco has no drive

[mr_p_j]

Hi everyone please can someone help me?

I have a 1993 discovery 200tdi, after a journey yesterday i got home put the brakes on an dipped the clutch i felt a judder and heard some odd clunks vehicle in reverse and started to reverse in to the drive, when I heard another odd noise, and completely lost drive! - I tried reverse, forward again nothing, I left it 10 mins or so went back to it, tried again and nothing.

By no drive I mean you can lift have it in any gear, engine running and lift the clutch pedal without it moving or stalling (the clutch pedal feels fine though)

I put it into low ratio and horray it moved back up the drive, after about 10 yards more noises and it lost drive again, leave it to cool and providing you are either pushing/pulling on the hi/lo range lever (with diff lock on) it will move a bit?

the previous owner had a new clutch 40-45k ago

I have been reading on the forums etc and see many possible causes, clutch center broke out, transfer box dead?

is there a way to remove the drive shaft and seperate the system to ease/reduce removal, drop out the transfer box to inspect it, leaving the gearbox and engine (poss bell housing) still in place? or get to the clutch without removing the engine or the whole gearbox, transfer box and bellhousing unit. (as I do not have an engine lift!)

thanks

PJ

[listerdiesel]

You can take the transfer box from the main gearbox, and in some situations it is the best option as it makes taking the main box out easier/lighter.

If you have lost drive in both high and low ranges, I'd check the obvious, which is the Hi/Lo linkage to the lever first. If not used/lubricated regularly it will seize up and you could just have a selector that is stuck between ratios.

Peter

[mr_p_j]

Cheers Peter / landrover network members

i do not tend to use lo range, and have not used it for several months and was not doing anything near that lever when it happened - I was physically reversing! - can it drop out of a ratio?

where do i get to the linkage to check it? - do I need to remove the gear lever gaters, cubby box, window switches section etc, plastic bit in the middle etc - or do you access it from underneath?

I guess the set up goes:
engine - bellhousing/clutch/gear box - transfer box - driveshafts?

If this is correct am i right to assume i remove the rear drive shaft, put a trolley jack/axel stand under the main box to take the weight loosen the transfer box and slide it towards the rear of the vehicle, then remove remove the gear box / bell housing to get access to the clutch?

when i pull/push hard on the hi/lo range lever from just starting i get drive until it gets warm?

I had some difficulty last week reversing it up onto some ramps, it needed lots of revs - could this of been the clutch starting to slip (it has also been smelling a bit gassy - its a diesel so it aint an lpg leak)

is it worth overhauling the handbrake assembly at this point also?

someone else has told me to check if the transfer box had oil in it/change the oil?

many thanks in advance

Paul

[mr_p_j]

For safety i did engage diff lock when it was up the ramps last week,
but did not alter the range if this helps?

PJ

[bananahead]

When you lose drive does putting difflock on make it go?

[listerdiesel]

For safety i did engage diff lock when it was up the ramps last week,
but did not alter the range if this helps?

PJ


Did you take it out again when you had finished?????

Peter

[mr_p_j]

thanks for getting back again

Bananahead - it does not make any difference it will only go when its cold and you are pushing or pulling hard on the drive ratio lever (with diff lock engaged or off!)

Peter - I took it out of diff lock ensured the light had gone out before letting it down off the ramps - this was only about 50-60 miles ago though?

many thanks

PJ

[mr_p_j]

Guys

Removed the middle bit of the console, stereo, cubbly box etc
checked the linkages to the ratio box and there is a little extra at the ends?

taken the inspection plate off the bottom of the transfer box, and removed the handbrake etc

I cannot seem to see anything moving in there when you move the hi/lo lever

the diff will turn freely until it goes into gear then it wont so perhaps the clutch is ok

there was quite a few filings on the filler plug

removed the plate on the top of the transfer box (above the handbrake)
and am going to try to inspect the top cogs and spline (coming from the gearbox

am i going in the right direction?

PJ

[listerdiesel]

More or less, if you have a lot of iron parts on the drain plug, it is probably time to get the box out anyway.

Peter

[mr_p_j]

here goes

got the transfer box off! spline on gearbox is ok, put the input gear on to the spline seperated from the transfer box and there is very little play in it

dont know if its right or not but there seems to be 3 positions on both the diff lock and hi/lo ratios? (on the box when turned with a spanner)

when you turn the ends (which connect to the drive shafts) the cogs inside do not always move? is this normal

also tried turning the spline coming out of the gear box - it moves freely until you put it in gear then it goes tight - is it worth trying this with a bit of force to see if it will skid/slip? (to check the clutch plate?)

many thanks in advance

Paul

[mr_p_j]

Peter

thanks for all the help and advice so far

just finished stripping the transfer box, and the "y" shaped locator that engages hi/lo in the bottom back of the box (behind the drive shaft row of cogs) has is a brass coloured rail with a hole drilled in it where the arm secures in - the grub screw had worked loose and was bearly making contact and almost slipping freely up and down the rail - causing it to slip in and out of range! (i think)

going to give it a clean with some brake cleaner and loctite it in, and reassemble the job

hopefully everything will work and thanks again

Paul