| Author | Message | ||
     JVelocet (Vracer) New Member Username: Vracer Post Number: 25 Registered: 06-2003 |
Some of the transfer cases used in the 95 Disco had trouble lubricating the top gear set in the transfer case. I found out the hard way and need to get a new one (which has been modified to solve this problem). My advice, keep those cases FULL and use the stickiest gear oil that climbs the best. I would even suggest an additive that would help the gear oil climb and cling and when you fill it feed the filler tube up to the top gear set. My case was full and this still happened. | ||
| Shaun Power (Shaunp) Member Username: Shaunp Post Number: 158 Registered: 05-2003 |
You just remove the gear and replace with the drilled one ( if the shaft is not stuffed). Can be done in the car takes about an hour. I have drilled the early ones but they are hard as. All cars with a transfer box with a serial number ending in less tan "f" are effected. | ||
| JVelocet (Vracer) New Member Username: Vracer Post Number: 26 Registered: 06-2003 |
Good info Shaun, but my box is toast, you shoud hear the noise it made on the way to the shop. But every other 95 owner would be smart to check their box and make this modification. It will cost me $1,900.00 dollars (US) to get the new box. | ||
| Brian Newport (Briann) New Member Username: Briann Post Number: 5 Registered: 03-2003 |
Make what modification? | ||
| Brian Dickens (Bri) Senior Member Username: Bri Post Number: 666 Registered: 08-2002 |
Why would landrover NOT make a recall on this? | ||
| Chris Browne (Chris_browne) Senior Member Username: Chris_browne Post Number: 299 Registered: 02-2003 |
Sounds like you're confusing the R380 problems with the t-box. Worst thing for a t-box, except for running low on fluid is not to run it in low range on a regular basis. ditto for the diff lock. Luckily I live on a dirt track | ||
| JVelocet (Vracer) New Member Username: Vracer Post Number: 27 Registered: 06-2003 |
Answer for the Brians: The modification that Shaun describes in his post, replacing the gear with the drilled one. I don't know why Landrover did not make a recall on this, but you are not alone in asking this question. | ||
| Dave Thomas (Davet) New Member Username: Davet Post Number: 7 Registered: 09-2003 |
Anyone have a writeup/how-to on replacing the gear with the t-case in the Disco? | ||
| Shaun Power (Shaunp) Member Username: Shaunp Post Number: 162 Registered: 05-2003 |
All transfer boxs with out a drilled input gear have this problem don't matter if it's an LT77,R380 or Auto box. Auto's don't suffer as bad. TDi 5speeds are the worst. The gear swap is easy. Remove the pto cover and bearing retainer and if every thing is neutral you just jiggle the gear and it slides out. The Modified gears have 4 10mm holes drilled in the spool to let splash into the shaft. You can drill your gear if it is not toast, be warned they are hard and you need a good drill and some drilling compound. If you buy a new gear you will need to also fit the bearings to it. replace it and your done. If the gear box splines are not totally stuffed you can fit a gear and half the back lash. | ||
| Ricky Smart (Rikstaboogie) New Member Username: Rikstaboogie Post Number: 15 Registered: 05-2003 |
errrr... thats the diagnostics done. :-) What are the symptoms? | ||
| Shaun Power (Shaunp) Member Username: Shaunp Post Number: 163 Registered: 05-2003 |
Heaps of back lash in the drive train until one day there is no splines left,it goes crash,grind and stops. This does no harm to the transfer box except for filling it with iron filings. The main shaft of the main gear box is what get stuffed. LT77,R380 5speeds behind TDIs died before 50k, some as low as 20k. V8 cars lasted longer due to the fact they are smoother and less gear changes ie less dropping of the clutch. Auto's due a more constant smooth power flow last ok. So little oil gets to the shaft that they are rusty when you check them if they don't have the mod gear. After the gear is changed they are fine. Some countries this fault was fixed under warrenty or were retro fitted , but lots of countries US included refused to admit the problem. My car was done under warrenty and I never had a problem (V8 5Speed). I've done a number of cars since that failed outside of warrenty period. If it fails in service you are up for a full main box rebuild to replace the main shaft. | ||
| Jim Taylor (Pug303) New Member Username: Pug303 Post Number: 1 Registered: 08-2003 |
Hi, there was a really simple fix available/possible. I have a 95 and fitted a small "slinger" onto the cover from the back of the transfer case (I believe you could buy these in the UK). It is just a spoon type thing that catches oil and runs it into the end of the splines. Whilst the bored gear is the best solution this cost nothing and works a treat. I now have well over 200,000km and it's all as tight as a drum. Cheers Jim | ||
| Bazzle (Bazzle) New Member Username: Bazzle Post Number: 4 Registered: 09-2003 |
I had a 94 TDI Auto, 240,000ks. I used to over fill the transfer case by a 1/2 litre or so when changing oil and drain excess out a couple of days later. Oil found its way to the splines. bazzle | ||
| Shaun Power (Shaunp) Member Username: Shaunp Post Number: 165 Registered: 05-2003 |
The oil feeder is still available in the UK they cost about $30 I think. I'll find the bloke who sells them and post the details. LR did this mod for a while as a quick fix I think. | ||
| Shaun Power (Shaunp) Member Username: Shaunp Post Number: 166 Registered: 05-2003 |
Here's where you get them http://www.steve-parker.co.uk/designed.htm |
