That seal is all chewed up because I struggled for 3 days trying to get it off, broke 2 princess auto pullers in the process LOOL... I'm super excited to watch this whole series
Hello Mike. And here comes another series of episodes for me to follow with great interest. As it happens, my Disco 1 after beeing parked for a fortnight, developed a new symptom, a shudder and a clunk as it takes up drive... having looked for signs, nothing obvious showed, but when i was crawling out of under it, the light of my torch catched a little shiny spot on the front propshaft universal joint... I grabbed the prop and massive play on the uj. Ordered some hd gkn and today i've changed them. The old ones were completely knackered, and i think that they were assembled by an ape with a sledgehammer. Hammer marks on the yokes, etc. Now it runs very smooth, no clunks and even 2nd gear shifts very nice. Sorry for the testament, but thanks to your videos, i was able to diagnose and repair. So, once again, thank you for your insights and expertise. Tata
I'll be watching this series with pen and paper to hand as i've decided to get my '96 TDi back on the road with it's knackered gearbox which i suspect has a broken shaft inside. It conked out a couple of years ago and during the search for a second hand gearbox i found one for £1700. Unfortunately it had a complete TD5 Disco 2 connected to it. Never really got on with it so sold it last November and now have developed the shakes due to having no Landy on the road! It'll be cheaper and quicker to sort out the Disco than my '61 S2 or '93 90 😁
I think I drained all my brass syncro cones out with an oil change in my old D1. We did an 1800klm trip with no clutch, (the release fork had broken, we had no option but to drive). Due credit to those R380 syncros, after driving all that way minus any clutch, (95% highway), the only problem seemed to be, it was sometimes a little "catchy" going first to second. The oil I drained out after that trip and before repairs was "liquid gold". Looking forward to seeing you strip this one down Mike.
Hi there, Just did a complete r380 and lt230 rebuild for my td5 a couple of months ago following your older vids (from 3 years ago or so). What a great tutorial that is!!! I also ordered the Ashcroft kits. I upgraded mine with the heavy duty r380 rear casing bearings and they have a larger outer diameter compared to standard bearings. This meant that I did sent the aluminium rear casing to Ashcrofts and they machined it so as the larger diameter heavy duty bearings would fit in. Also the oilpump has a larger diameter. Ashcroft sends a new larger oilpump housing with the kit and you would just have to 'build' in the old standard oil pump 'gear' into it. As said I did the major r380 rebuild, with new shafts, swapped out all worn components, upgraded to the V8 5th gear, heavy duty bearings, improved oil feed ring in rear casing, Arb diff into the lt230, shimming up and all without special mechanical knowledge beforehand. Combination of workshop manual and Mike's videos will guide you through the process with ease. Only thing I did not find mentioned anywhere (I might have overseen) is that the 5th / reverse synchro hub should be mounted with the 5 halve moons pointing towards the reverse gear and not the 5th, other wise you won't be able to get the circlip in place (all other hubs are mounted with halve moons pointing towards representative gear). Lovely to drive with the new transmission! And more importantly it gives a fantastic boost to experience you can do it in your own little back shed staring at great tutorials. Thanks Mike! With love from Belgium.
Well done! Yes there is a lot of confusion with the 5 half moons as they point the wrong way, however I think the outer ring of the syncro can be fitted either way round, but the inner can only go one way
Hi Mike. Always enjoy watching your videos from South Africa .. I am a Land Rover enthusiast and a Mechanic myself .. your my Hero! Thanks for all the knowledge
Hi Mike. Thanks for all the great vids. I opened my 98 D1 gearbox for a loose layshaft nut and decided to replace the bearings. Since then it had an intermittent 2nd and 3rd gear grating. Five more gearbox strip downs (plus an Ascroft kit), two done by gearbox specialists and two clutch changes, I still had the intermittent grating gear change. Five years on and the left side cv developed a small bit of play. So small I had to clamp the shafts to the housing to determine that the play was in the cv and not in the diff. I then decided to change both Shafts, CV's, Drive flanges and since then the intermittent grating has disappeared.
Looking forward to this as my td5 box is on the way out. Compared to modern engines and the 2.4 puma fitted to later defenders the td5 isn’t a bad lump. My daily is a td5 and they’re not bad. Cheers for this series Mike
I think the LT95 was a 'blank sheet of paper' box, not adapted from other vehicles, but with an integral transfer case it was limited to only a few ratios
Finaly got a defender only one i could offord was a td5 only start when it feels like it.What is the correct battery for it mine have a 650 in 12v 90ah/20hr 16min/rc 750/cca all things i see shows it must have a 658c
To be honest in North America there is a different standard for battery sizes and I am out of touch with rest of world types, so for here, a Defender battery would be 750 cold crank minimum, but with the newer AGM batteries become more affordable, this can be up to 1500cc - so the bigger the better Normally Td5 are good starters, so check the glow plugs first ( there are only 4 fitted )
@@BritannicaRestorations Yeah. I got one for my D1 as the original one was destroyed, there wasn't anything left to rebuild.. It still worked out cheaper than getting one built here in Oz. And of course it is perfect. Dave knows his stuff.
'I can't throw it over next doors fence, it's looking a mess now' 😁 classic. Wish I could send you my LT85. It's noisier than me shouting about the plandemic for the last two years.
@BritannicaRestorations oh ok thnx. I really love your videos. You show so much detail. I've got a 300tdi engine which needs rebuilding. After seeing your videos I felt I could do that if I carefully follow your steps. So ive bought everything needed but now I'm terrified to try it lol
King Mike what do you think I have almost 500k km on my TD5. Lil crunchy second gear witch I usaly skip. Is this smething that is awaiting me in near future or not. Cheers King Mike. 🥃
I really admire your skills, but please have some practice on presentation skills as well. It is a UA-cam channel for watching and maybe learning in some cases 😊
That seal is all chewed up because I struggled for 3 days trying to get it off, broke 2 princess auto pullers in the process LOOL... I'm super excited to watch this whole series
Hello Mike.
And here comes another series of episodes for me to follow with great interest.
As it happens, my Disco 1 after beeing parked for a fortnight, developed a new symptom, a shudder and a clunk as it takes up drive... having looked for signs, nothing obvious showed, but when i was crawling out of under it, the light of my torch catched a little shiny spot on the front propshaft universal joint... I grabbed the prop and massive play on the uj.
Ordered some hd gkn and today i've changed them.
The old ones were completely knackered, and i think that they were assembled by an ape with a sledgehammer. Hammer marks on the yokes, etc.
Now it runs very smooth, no clunks and even 2nd gear shifts very nice.
Sorry for the testament, but thanks to your videos, i was able to diagnose and repair.
So, once again, thank you for your insights and expertise.
Tata
Thanks!
I'll be watching this series with pen and paper to hand as i've decided to get my '96 TDi back on the road with it's knackered gearbox which i suspect has a broken shaft inside.
It conked out a couple of years ago and during the search for a second hand gearbox i found one for £1700. Unfortunately it had a complete TD5 Disco 2 connected to it. Never really got on with it so sold it last November and now have developed the shakes due to having no Landy on the road! It'll be cheaper and quicker to sort out the Disco than my '61 S2 or '93 90 😁
I think I drained all my brass syncro cones out with an oil change in my old D1. We did an 1800klm trip with no clutch, (the release fork had broken, we had no option but to drive). Due credit to those R380 syncros, after driving all that way minus any clutch, (95% highway), the only problem seemed to be, it was sometimes a little "catchy" going first to second. The oil I drained out after that trip and before repairs was "liquid gold".
Looking forward to seeing you strip this one down Mike.
Hi there, Just did a complete r380 and lt230 rebuild for my td5 a couple of months ago following your older vids (from 3 years ago or so). What a great tutorial that is!!! I also ordered the Ashcroft kits. I upgraded mine with the heavy duty r380 rear casing bearings and they have a larger outer diameter compared to standard bearings. This meant that I did sent the aluminium rear casing to Ashcrofts and they machined it so as the larger diameter heavy duty bearings would fit in. Also the oilpump has a larger diameter. Ashcroft sends a new larger oilpump housing with the kit and you would just have to 'build' in the old standard oil pump 'gear' into it. As said I did the major r380 rebuild, with new shafts, swapped out all worn components, upgraded to the V8 5th gear, heavy duty bearings, improved oil feed ring in rear casing, Arb diff into the lt230, shimming up and all without special mechanical knowledge beforehand. Combination of workshop manual and Mike's videos will guide you through the process with ease. Only thing I did not find mentioned anywhere (I might have overseen) is that the 5th / reverse synchro hub should be mounted with the 5 halve moons pointing towards the reverse gear and not the 5th, other wise you won't be able to get the circlip in place (all other hubs are mounted with halve moons pointing towards representative gear). Lovely to drive with the new transmission! And more importantly it gives a fantastic boost to experience you can do it in your own little back shed staring at great tutorials. Thanks Mike! With love from Belgium.
Well done!
Yes there is a lot of confusion with the 5 half moons as they point the wrong way, however I think the outer ring of the syncro can be fitted either way round, but the inner can only go one way
Hi Mike. Always enjoy watching your videos from South Africa .. I am a Land Rover enthusiast and a Mechanic myself .. your my Hero! Thanks for all the knowledge
Thanks Lawrence!
Ooft, TD5 stuff, you're spoiling us. 👍🏻🏴
Sorry!
Hi Mike 👋 just saying hi and thanks again 🤔 great video as always 👍👍👍🇬🇧🇬🇧🇬🇧🚌🚌🚌
Glad you enjoyed it
Hi Mike. Thanks for all the great vids. I opened my 98 D1 gearbox for a loose layshaft nut and decided to replace the bearings. Since then it had an intermittent 2nd and 3rd gear grating. Five more gearbox strip downs (plus an Ascroft kit), two done by gearbox specialists and two clutch changes, I still had the intermittent grating gear change. Five years on and the left side cv developed a small bit of play. So small I had to clamp the shafts to the housing to determine that the play was in the cv and not in the diff. I then decided to change both Shafts, CV's, Drive flanges and since then the intermittent grating has disappeared.
How odd!
Sounds like a tight spigot bush ,I had similar on1 and 2 gears they are very soft and after insertion ream it out also lubricate down hole
@@simonrowlands7472 That was unfortunately not the fault on mine. Changed the bush with each clutch.
Looking forward to this as my td5 box is on the way out. Compared to modern engines and the 2.4 puma fitted to later defenders the td5 isn’t a bad lump. My daily is a td5 and they’re not bad. Cheers for this series Mike
I think the LT95 was a 'blank sheet of paper' box, not adapted from other vehicles, but with an integral transfer case it was limited to only a few ratios
@@BritannicaRestorations yes an excellent gearbox but bloody heavy and awkward to move about
Fantastic job! 👍🏻💪🏼
Thank you! Cheers!
Not too often you'd have to replace a gear nowadays I guess. Some gearboxes have synchros on reverse too.
R380 has a reverse synchro but it surprising how chewed up they can get
Good work
Thank you! Cheers!
Finaly got a defender only one i could offord was a td5 only start when it feels like it.What is the correct battery for it mine have a 650 in 12v 90ah/20hr 16min/rc 750/cca all things i see shows it must have a 658c
To be honest in North America there is a different standard for battery sizes and I am out of touch with rest of world types, so for here, a Defender battery would be 750 cold crank minimum, but with the newer AGM batteries become more affordable, this can be up to 1500cc - so the bigger the better
Normally Td5 are good starters, so check the glow plugs first ( there are only 4 fitted )
Great video as per. Q. What camera do you use?? Cheers 👍
Canon VIXIA HF r800 camcorder - tough bit of kit for the shop!
TD5 Yippy
Great video, Mike, but I see the kit looks a bit pricy - even for us in the UK. Would it be better to take a chance on another used one?
If you can find one - always a risk
Not an easy job to change the gearbox 2 or 3 times until you find a good 'un
@@BritannicaRestorations Fair comment, Mike - I suppose you do not know what you may inherit! At least if you fix it, you know what you have.
That's true Dave - see what this box is like when I get into it!
TD5s aren't exactly thick on the ground over there, are they Mike? Pity, as they are way better than the V8s.
Like chickens teeth...
Option was to send it to me, or get an Ashcroft one plus shipping plus core charge = $$$$$
@@BritannicaRestorations Yeah. I got one for my D1 as the original one was destroyed, there wasn't anything left to rebuild.. It still worked out cheaper than getting one built here in Oz. And of course it is perfect. Dave knows his stuff.
'I can't throw it over next doors fence, it's looking a mess now' 😁 classic. Wish I could send you my LT85. It's noisier than me shouting about the plandemic for the last two years.
I have 2 on the shelf here!
@@BritannicaRestorations Goodness, that would be grand, but no doubt very cost prohibitive getting one to Cumbria.
It would be cheaper to move Cumbria to Quebec...
@@BritannicaRestorations 🤣
how many splines are on the R380 output mainshaft
10
What's the difference between an r380 from a td5 to one from a 300tdi
The shaft from the clutch to the gearbox is longer and the ratio could be different
@@BritannicaRestorations so would the shafts be easy to swap
No - you will have to have the matching teeth numbers on the input and layshaft - can get expensive! Can of worms!
@BritannicaRestorations oh ok thnx.
I really love your videos. You show so much detail.
I've got a 300tdi engine which needs rebuilding. After seeing your videos I felt I could do that if I carefully follow your steps. So ive bought everything needed but now I'm terrified to try it lol
Don't be afraid to ask!
King Mike what do you think I have almost 500k km on my TD5. Lil crunchy second gear witch I usaly skip.
Is this smething that is awaiting me in near future or not.
Cheers King Mike. 🥃
Try flushing 2 or 3 times the oil first - sometimes works wonders on R380!
@@BritannicaRestorations Thanks for the tip.👍
Will try this.
Cheers.🥃
I much much prefer the good old lt95 4 speed box much tougher
I really admire your skills, but please have some practice on presentation skills as well. It is a UA-cam channel for watching and maybe learning in some cases 😊
Ok thank you