How to find out if you have a good used gearbox and transfer case for a Defender

/ britrest
www.subscribestar.com/britrest
www.paypal.me/britrest2018
Your support is appreciated!
If you have a Defender/Tdi problem and do not know how to fix it, drop me a line!
Maybe I can help!?
[e-mail]
Send me a postcard for my wall!
Britannica Restorations Ltd
9 Ch. Rawson
Sherbrooke
Quebec
J1M2A3
Canada

[@harveysmith100]

After the paranoia set it when you went to drain that transfer box and a dribble came out, I vowed to change the oil in mine. Just got back from picking up some fresh gear oil and up popped this video. Less paranoid now that I have the oil but after seeing those cogs I must get it changed!

[@BritannicaRestorations]

How many stitches in time were saved? I should get sponsorship from Castrol! lol Mike

[@harveysmith100]

@@BritannicaRestorations Firm believer in the stitch in time. Cheers Mike

[@curtis8988]

Mike, these are so incredibly helpful. I'm about to take a part a LT 230 on my 1996 landcover disco 1 i bought for overloading and this has set me miles ahead. Thank you so much for taking the time to do these!

[@BritannicaRestorations]

You're welcome!

[@curtis8988]

@@BritannicaRestorations Quick question for you Mike. In my 1996 Disco 1, it was reported they "rebuilt the engine" 5k miles ago. What should I do in terms of going over it to see if they've done enough?

[@BritannicaRestorations]

Pretty tough question as a 'rebuilt' engine could be from a complete overhaul and machining of every part possible, to a steam clean and a coat of paint!

[@the_hamrat]

Thanks Mike, this video came in useful as my Discovery 2 decided it was going to eat its transfer case (a tooth came off and destroyed the inner workings, it sounded like someone was firing a machine gun) and I had to source a recon unit. Good video as always

[@andicog]

Great video, didn't realise that the military LT77 was different, know mine has a big gap in ratios between 2nd and 3rd, screams it's head off in 2nd on a steep hill but go for 3rd and it's too tall to pull. Better since the 300tdi. I've got the disco transfer box, sits happy on the motorway now. Keep up the good work Mike.

[@BritannicaRestorations]

Thanks! Mike

[@zedman442]

Great tips mister! There are so many little intricacies with LR gearboxes and transfer boxes. I have never owned one but want to swat up up best I can before I even consider ownership!

[@davidwoods80]

Highly valuable information! Thanks Mike!

[@BritannicaRestorations]

If you remove the cover and have a look you can save a heap of time and money!

[@sukottora]

I have never seen a bad video from this feller... I'll keep looking though.

[@emmittparker549]

i dont mean to be so offtopic but does someone know a tool to get back into an instagram account..? I was dumb lost the login password. I appreciate any assistance you can give me

[@maximilianjulian5426]

@Emmitt Parker instablaster ;)

[@emmittparker549]

@Maximilian Julian I really appreciate your reply. I found the site on google and im in the hacking process atm. Takes a while so I will reply here later with my results.

[@emmittparker549]

@Maximilian Julian it worked and I actually got access to my account again. I'm so happy! Thank you so much, you saved my ass :D

[@maximilianjulian5426]

@Emmitt Parker You are welcome =)

[@sanatandharma4435]

It is amazing to learn all of this, thankyou! Some thing been running through my mind are that vehicles, not just LR's are complicated things, made up of thousands of parts. Also when you removed the seat bulkhead on the 90 to improve leg room you cut through the metal. The Aluminium used is quite thick and sturdy. Landrover's really are bolted and riveted together and are customisable to individual wants and needs. Many thanks, I am learning a lot.

[@BritannicaRestorations]

You're welcome Mark!

[@bubblyjuice6234]

Cracking video, very useful and perfect timing too - I've just got a 2nd hand disco transfer box for my 110 - to do this next month. Cheers Mike.

[@BritannicaRestorations]

You're welcome Paul! Mike

Hi Mike and thanks for making this video and more great tips 🤔 must keep this one 👍thanks 👍👍👍

[@BritannicaRestorations]

Thanks Denis! More to add to the library! Mike

[@myysterio2]

My 300tdi R380 had the old gear in it when I got it and it was still functioning at 140k miles. Engine was completely unmodified from OEM. I still got the gear in my garage.

[@treewrightz4058]

great tips from the gearbox maestro ;0)

[@BritannicaRestorations]

More this week on this project!

[@susanamelody7319]

Thanks excellent video!!!!!

[@axelboldt5101]

Thanks a lot , now my Discovery 2 has Gearboxproblem I have seen a lot dirt ion the magnetic oilscrew so I hope it will run a liitle longer till I get money together!!!

[@BritannicaRestorations]

It is common to find a few magnetic particles on the plug, but not teeth or bearings!

[@ForemanAndWilmsAdventures]

Thanks again for the enlightenment.

[@BritannicaRestorations]

My pleasure!

[@888johnmac]

braver than me .. when i'm using a diesel-fired hot water cleaner I need a full face visor & oilskins

[@fionanokelly]

I'd love to see a video of you taking down the transfer box on that disco 1

[@BritannicaRestorations]

It was a total bitch to get out as everything was rusty Was under a bit of pressure to get the box out so it could be taken back to Ontario so no time to film

[@roberthughes6240]

if I were to check mine and it was okay but lacked the holes can they just be drilled or are there other differences to the gear? great video, thank you.

[@jamesbarker4808]

Brilliant video had me hooked. Your chipper is up must be spring!?

[@BritannicaRestorations]

Money coming in at last!

[@thelonemoomin]

If you dont have access to a steam cleaner I've always found Jizer (snigger) degreaser to work more than wonders. My old series 3s gearbox had a quarter inch coating of oil and dirt on it. One application of Jizer and a scrub and hose down it looked like new. ....... which couldnt be said for the driveway below 😫🤣

[@darland3821]

One of the first jobs I did on a Disco 1 I bought was to jet wash the engine. Went straight through the front of the (rusty) sump pan. By the time i had run to get a tray I had several litres of black oil on the nicely block paved drive. Mrs Darland was not happy.

[@thelonemoomin]

@@darland3821 🤣 small oil stains can be removed from block paving using a blowtorch to vapourise the oil. But several litres thats another thing.

[@darland3821]

@@thelonemoomin indeed it was. Most of the weekend!

[@canamsteve]

I had my R380 rebuilt using parts from Ashcroft (layshaft bearings were getting noisy) and had the cross-drilled xfer gear put in at the same time. Amazingly enough, LR has somehow managed to reproduce the same issue in Puma Defenders - both 2.4 and 2.2 I'm told. One friend is now on his third gearbox (stripped splines) and has had me deliver yet another custom Ashcroft fix. How can they make the same hugely damaging mistake three times? Watching this video reminds me I have another extra, which I think came from a South African Landy shop in BC. That's the extended oil sump for the xfer case with cooling fins. Not sure the fins do much, but the added lubricant can't hurt in the heart and deep sand. Mine regularly gets used at +40C

[@ArloDahMan]

Elder engeneers took some informations when retired. New engeneers don't know this proble? Maby this construction had happend on the evening at the year 2k-problem was pronounced? I don't know. Sometimes both of the two shafts are running in line for 200.000km with no issues! On the other hand there are several owners changing every 20.000km the extanding shaft. First there is no grease anywhere! And second the centers of the shafts are too much offset sometimes!

[@BritannicaRestorations]

I am quite surprised that LR have not had a class action suit issued on them due to known issues that they continue to manufacture You would NEVER get this issue with a Toyota Over the years it must have cost million to LR owners to fix these problem - and all it took was 4 holes in a gear

[@SirAmikVase]

Any recommendations for what to check when buying a series 2/2a (pre full synchro) gearbox? Can't imagine there's an easy way to check 3rd/4th isn't going to jump out on over run. Thanks 👍🏻

[@BritannicaRestorations]

You are correct - without a strip down it is had to say that they are like

[@amifan5566]

Hi Mike. Now I am becoming expert on landrover thanks to you. I am your follower and I really appreciate what you are doing. My name is Benami and I am from Ethiopia and I have a Defender 300Tdi 110 1997 which I bought recently in auction. When I bought it it has been standing for seven years without use. I checked all the oils I put new battery and it started at once. But now because of a sound in the transfer box I opened it and I found a big gap in between the two cone shaped bearing on the input gear. The spacer or shim is less than 3mm. which the factory recommends upto 4mm. My qestion is that is the shims or spacers on both sides or in one side? Because I only found in one side. Thank you so much.

[@BritannicaRestorations]

There are only shims on one side of the input gear

[@amifan5566]

@@BritannicaRestorations thanks for your quick reply.

[@doyledesign1676]

Hi Mike. Was their a manufacturing year when they started making the transfer box gear shaft with the oil holes a stock item or has it always been an upgrade from the original style. Jim

[@BritannicaRestorations]

Very hard to say - I have an idea early Td5 were not drilled - but I only heard about this not seen any Td5 here with that issue - so that would be around 1999

[@bosniamenrepairmen5810]

I just buy transfer box ratio 1.667 on my vehicle the ratio is 1.410 is that ok? Do i have to change gears inside Thanx for all videos

[@BritannicaRestorations]

It should be a straight swap - no need to play with the gears

[@fysioalb]

Newbie-question here - I have a reconditioned lt77 that came without transfer that I`m planning to use with my old transfer case. So, I should look at the transfer gear and check that the splines are good and that it has holes in it? And if it doesn´t I should have holes made in it? Thanks for your advice

[@BritannicaRestorations]

Yes check for the holes - it is very difficult to drill the holes as the gear is hardened - you can do it on a slow drill press with masonry bits and a lot of oil and patience On the very early gears there is no pre-drilled gear available - you have to check the serial number of the box and tooth count of the gear to find out

[@markmulvaney5497]

you saved my bacon again, 😀 question i have a new input shaft for my transfer box 26 splines was trying top put it in wrong way and ring cover would not go fully home, good job really as you mention in this video can go both ways but only run on part of the teeth, PTO to the back, problem is my new 26 teeth input shaft wont go in seems to go past the first cog but not the second one my new shaft seems wider just the cog it self shaft same length any ideas old input shaft goes straight in.

[@markmulvaney5497]

LT230

[@BritannicaRestorations]

Transfer box serial number would help

[@markmulvaney5497]

@@BritannicaRestorations all ok now it seems the new shaft was just tight block of wood and hammer did the trick got it past the inner cog then pushed it home, Box number 20D029509B good thing is it now drives,

[@johnniehunter4991]

Hi Mike would you have a lt77 defender bellhouseing that you want to part with

[@BritannicaRestorations]

I think so - will have to look when I dig out my container doors - email me

[@federicoacker5672]

Hi Mike, I ask for your advice: I been offered a RRC ´95, 3.9, in very good condition, rust free, very well take care of, almost none off-road use. But I´m worried about the transmission, because it have 200.000 kms in the clock... So chain, and specially the Viscous Coupling must to be at the end of its life (the seller does not have a record of service). I´m been searching in the web, and as far as I can see, there are no more VC available brand new (same OEM). Craddock have re manufactured in stock (500 pounds). Ashcroft doesn´t have it in stock, they only do it in exchange. So the thing is: it is worth to service that transmission? or perhaps be a better choice find a Discovery transfer and replace the thing? What do you think? I know you are going to say: Walk Away from a RRC !, but I really love RRCs, and the frame/body of this car is worthwhile, but I don´t know... Let me know you´r thoughts. Thank you!

[@BritannicaRestorations]

If it is complete and rust free then it should be good - the 3.9 was not a bad motor - just pay attention to the cooling system Maybe a D1 transfer is a better idea - those high mile VC transfers will be a nightmare to overhaul - for me they go in the furnace if they have issues

[@federicoacker5672]

OK Mike, I will. I have to travel couple of hundred kms to test it, So may be when the old COVID let me... I´ll see. Thank you! Cheers!

[@broli85]

do you have a video on how to check a second hand r380, without the transfercase? about to buy a second hand unit and would like to know how I can make sure i do not install a busted one...

[@broli85]

my current gearbox is very noisy, gears are sticking, second has a mind of its own on when it wants to go in or not and one time it seized while pulling off on first

[@BritannicaRestorations]

Try flushing the oil and see the difference - I have known a few R380's can have a dramatic change once flushed of old oil - you may have to change it 2 or 3 times - may be cheaper than changing the transmission

[@broli85]

Thanks for the reply. Opened the gearbox and found out that i have a few issues.. the pil feed ring had turned and was not lubricating well. Ended up with overheated shaft, overheated 4th synchro hub and a failed bearing. I plan on fixing it but was wondering if you have any tips, or videos, on fitting this oil pickup ring. Im getting an ashcroft one as i think it is a better design

[@dariuszrad2661]

Mike i oto chodziło.

[@rosabella..threadsofpurelu4382]

"uneconomical repair " - you mean "stuffed"....

[@BritannicaRestorations]

Politely - yes!

[@arrowthruhead8117]

I have put that the wrong end inn , awful clunk .....☹🙈

[@BritannicaRestorations]

If you put it in the wrong way you will destroy the intermediate gear!

[@arrowthruhead8117]

@@BritannicaRestorations now i can't get it out, how to get it out? Do you have any ide?