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Lambley

Member Since: 20 Apr 2013
Location: Mid Devon
Posts: 1435

Td gearbox question

I've got an old pickup that I use regularly for fishing trips etc, it's in great condition and only done 68k miles which has to be low for a 1989 vehicle.
The only problem with it is the gear change is sloppy, I have to be steady on the clutch when changing and 'ease' the clutch out gently to avoid a 'clunk'.
I've not had the box or transfer box off yet but I suspect the mainshaft is worn. If that's the case - is it easier to buy a recon gearbox and be done with it?
Could it be something else? I know it's difficult without having a good look but wondered if anyone with an LT77 gearbox had had a similar problem and sorted it?

3rd Jun 2014 1:13pm

diesel_jim

Member Since: 13 Oct 2008
Location: hiding
Posts: 6092

Could also be propshaft UJ's or splines, and the drive hubs. these wear a bit and give a really bad "clunk",

Or a combo of all of the above.

3rd Jun 2014 2:04pm

Lambley

Member Since: 20 Apr 2013
Location: Mid Devon
Posts: 1435

I've just had a look underneath, the UJ's look ok and no slack, the front prop moves more and clunks a bit when turned by hand, the rear prop moves but a lot less with no clunk. Any idea's?

3rd Jun 2014 2:55pm

Diablo

Member Since: 26 Oct 2011
Location: Basingstoke
Posts: 335

1984 Defender 90 200 Tdi SW Keswick Green

Play in the diffs or hub driving member, or both.

3rd Jun 2014 3:19pm

rallysteve

Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2227

2002 Defender 110 Td5 DCPU Keswick Green

Have you checked the rear a-frame ball joint. This made an aweful clunk on gear changes in ours but had no real visible play until I got a HUGE pry bar on it - the play was obvious then.

Steve 02' 110 TD5 Double Cab Rebuild Thread

3rd Jun 2014 3:53pm

Lambley

Member Since: 20 Apr 2013
Location: Mid Devon
Posts: 1435

Thanks Steve, yes the A frame joint is new about 3 months ago, that's fine but thanks for pointing it out. It's more of a slight metallic clunk when the clutch is released, if done slowly then it's not a problem, and when driving there is no sloppiness, just when the clutch is released, especially when pulling away.

3rd Jun 2014 4:02pm

roel

Member Since: 08 Aug 2009
Location: Lelystad
Posts: 2039

There is a round cover on the back of the transfer box behind that is a cogwheel that tranfers the drive from the gearboz to the transfer box. These wear fast by lack off lubrication specially if not used that often. Roel

1984 90 2.5 na Diesel - RR V8 (1994-2001)
1997 Camel Trophy Discovery 300TDI (2001-2009)
2005 G4 Discovery III 4.4 V8 (2008-2018) It's gone but it still hurts.
2003 90 Td5 (2009-now)

3rd Jun 2014 4:20pm

Lambley

Member Since: 20 Apr 2013
Location: Mid Devon
Posts: 1435

Thanks Roel, is that something that can be replaced easily? Will I be able to tell if there is wear by taking the cover off and looking inside? I've swapped a transfer box off before but never had the cover off.
I've just been underneath again and it looks like the transfer box might have wear issues, there's quite a bit of movement when grabbing and turning the props by hand, the clunk seems to be coming from inside the transfer box, more so when turning the front prop.

3rd Jun 2014 4:28pm

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