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anotherrick



Member Since: 02 Feb 2024
Location: Lancashire
Posts: 30
 1997 Defender 110 300 Tdi CSW Rioja Red
Can't engage gears (R380)
So after my gearbox issues a couple months ago I decided it'd be easier to just replace the gearbox and transfer box and whilst i was at it I bought a clutch kit & fork too.
Left my car at the garage as I don't have the facilities or space for that kind of job.
Anyway contact the garage today to arrange collection and he tells me that the car won't engage gears when the engine is running unless the transfer box is in neutral. Everything engages smoothly when the engine is off.

Car is a 1996 110 300tdi, the clutch was a lof as was the hd selector fork. Master cylinder is a couple of years old, slave cylinder does look like it needs replacing.
Gearbox and transfer box were recon items from a reputable supplier.

Did a quick search but that thread didn't have a resolution.

Anyone have an idea what the issue might be?

Thanks.
Post #1038737 29th Jun 2024 7:17pm
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landy andy



Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5725
2006 Defender 110 Td5 USW Zermatt Silver
If gears can be selected when engine off and not when on, that indicates to me that the clutch is not disengaging between engine and box.
Post #1038741 29th Jun 2024 7:51pm
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anotherrick



Member Since: 02 Feb 2024
Location: Lancashire
Posts: 30
 1997 Defender 110 300 Tdi CSW Rioja Red
What could be the cause as everything is practically new
Post #1038743 29th Jun 2024 8:44pm
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diesel_jim



Member Since: 13 Oct 2008
Location: hiding
Posts: 6093
United Kingdom 2006 Defender 110 Td5 SW Epsom Green
fitted the clutch plate the wrong way round? I did it to a Td5 I was building lol
Post #1038749 30th Jun 2024 6:40am
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anotherrick



Member Since: 02 Feb 2024
Location: Lancashire
Posts: 30
 1997 Defender 110 300 Tdi CSW Rioja Red
Not Impossible but they say not. Did offer to check though.
Post #1038807 30th Jun 2024 8:02pm
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bankz5152



Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2173
2004 Defender 110 Td5 DCPU Epsom Green
Have you adjusted the clutch pedal Instagram @defender_ventures
Empire Tuning - Agent
Post #1038853 1st Jul 2024 10:25am
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anotherrick



Member Since: 02 Feb 2024
Location: Lancashire
Posts: 30
 1997 Defender 110 300 Tdi CSW Rioja Red
Yeh was one of the first things tried
Post #1038872 1st Jul 2024 2:48pm
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landy andy



Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5725
2006 Defender 110 Td5 USW Zermatt Silver
Give Luke at LOF a call. Explain the situation to him and ask his advice.

He is a really really nice bloke that will have time for you.
Post #1038873 1st Jul 2024 2:55pm
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Oldowner



Member Since: 26 Dec 2018
Location: South west
Posts: 625
United Kingdom 2007 Defender 90 Puma 2.4 HT Aintree Green
Engage first, then start the engine with clutch depressed, try pulling away. If it works as it should, but won’t select gears when running, usually caused by new clutch plate on worn flywheel, more common now with all Tdi’s getting old and worn out, the new clutch plate drags on high spots or ridges on the flywheel surface so the gearbox internals are still turning when the clutch is depressed. Clutch plate will bed in and gears will select again.

Regardless of the fault the garage should be able to figure the fault out however majority of garages now are clueless in the operation of a vehicle without being able to plug in diagnostic scanner to tell them what sensor to change, Land Rover specialists included
Post #1038920 2nd Jul 2024 2:49am
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anotherrick



Member Since: 02 Feb 2024
Location: Lancashire
Posts: 30
 1997 Defender 110 300 Tdi CSW Rioja Red
landy andy wrote:
Give Luke at LOF a call. Explain the situation to him and ask his advice.

He is a really really nice bloke that will have time for you.


Spoken to him, he's a nice guy and very helpful. He said its unlikely clutch is in backwards as it'd be very difficult to do that on a tdi, he also said it could be out by 60 degrees which can cause issues.
Post #1038939 2nd Jul 2024 9:33am
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anotherrick



Member Since: 02 Feb 2024
Location: Lancashire
Posts: 30
 1997 Defender 110 300 Tdi CSW Rioja Red
Oldowner wrote:
Engage first, then start the engine with clutch depressed, try pulling away. If it works as it should, but won’t select gears when running, usually caused by new clutch plate on worn flywheel, more common now with all Tdi’s getting old and worn out, the new clutch plate drags on high spots or ridges on the flywheel surface so the gearbox internals are still turning when the clutch is depressed. Clutch plate will bed in and gears will select again.

Regardless of the fault the garage should be able to figure the fault out however majority of garages now are clueless in the operation of a vehicle without being able to plug in diagnostic scanner to tell them what sensor to change, Land Rover specialists included


This seems very likely given the vehicles age/mileage.

I'll be passing all the info onto the garage today.
Post #1038940 2nd Jul 2024 9:34am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17443
United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
anotherrick wrote:
... it could be out by 60 degrees which can cause issues.


What does this baffling statement mean?
Post #1038945 2nd Jul 2024 10:38am
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TexasRover



Member Since: 24 Nov 2022
Location: Paris
Posts: 1084
France 2002 Defender 110 Td5 DCPU Chawton White
So hang on I don't really understand the problem. You used reputable parts and a shop and the shop is telling you that after them assembling it it does not work.

Sooo, 'shop', what are you going to do about it? Take it apart again I assume and fix it.

So what is the problem, they took it apart and could not find an issue? What are they proposing?
Post #1038954 2nd Jul 2024 11:56am
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TexasRover



Member Since: 24 Nov 2022
Location: Paris
Posts: 1084
France 2002 Defender 110 Td5 DCPU Chawton White
blackwolf wrote:
anotherrick wrote:
... it could be out by 60 degrees which can cause issues.


What does this baffling statement mean?


I assume the mounting of the pressure plate assembly? You would think dowels and bolt holes would prevent that.
Post #1038955 2nd Jul 2024 11:58am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17443
United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
How would that make the slightest difference? Question
Post #1038966 2nd Jul 2024 3:48pm
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