TD5 Gearbox woes - Ford Forums - Mustang Forum, Ford Trucks, Ford Focus and Ford Cars

Tote · 10-27-2002, 15:41

Just got my 2000 Disco back after a complete gearbox rebuild at 84000 Kilometres. It appears that the output bearing collapsed and the resulting crap went right through the box necessitating a complete rebuild. Has anyone else had issues with their 5 Speed boxes ?
Regards,
Tote

xsavier · 10-29-2002, 08:31

The R380 box although stronger than the LT77 (380 Newton Metre input) had a nasty tendency to wear output shafts.

If you lift off the inspection panel you may be able to see the wear. This is caused by the output shaft not being correct oiled.

The fix the problem (depending on VIN) cross drill the shaft or fit a splash plate.

Cheers,

Neil

Tote · 10-29-2002, 18:41

AAAh... everything becomes clearer. Since the box was rebuilt by the dealer do you know whether the replacement output shaft they fitted would have had a mod?
Could the wear be minimised by changing to a different lubricant ? I suspect that a couple of trips to Queensland in the last 12 months may have contributed to its demise. I was doing 120 Km/h for six and seven hour days in 35- 40 C temperatures. I did blow the rubber pipe out of the turbo during one of these trips and I suspect that was due to the high operating temperatures.
Thanks for the reply
Regds,
Tote

xsavier · 10-30-2002, 00:06

Hi,
The sustained high speed running would certainly accelerate the wear.
It�s a well-known fault with the gearbox so the dealer may well have fitted the mod. I�d stick to the ATF lubricant as EP 90 makes the �box like stirring treacle and any lighter would not offer enough protection.
If you can find out the VIN number I�ll have a gander on some other UK forums to see when it was made and if it was affected.
Cheers,
Neil

10-30-2002, 06:39

Hi Tote,

Your Disco should have the updated gearbox in it as its a 2000 MY vehicle. I think the mod was made around 1997-98 so the rebuild should be of the same quality.

It seems a wee bit soon for a 2000 vehicle to be showing signs of this problem though, and if it was this than you would have noticed a "clonk" sound from the rear of the box every time you pulled away from a standing start. The problem is caused by a lack of oil getting to the splines on the end of the output shalft where it mates with input gear on the transfer box.

The fact that the output bearing collapsed may only indicate an exessive ware or inferier part problem with the bearing and not with the shaft.

There you go, clear as mud

xsavier · 10-30-2002, 07:12

LR been keeping secrets from me, yours is an S1 like mine which was ended in 1998.

I usually take clonks from the rear as the A-Frame joint.

Only the VIN will tell.

Cheers,

Neil
Don't think I could get any more animation if I tried .

10-31-2002, 18:01

I think the shaft oil problem was rectified before the end of the series 1 Disco.

The "clonk" comes from the rear of the gearbox and not from the rear axle, I had it on my LR90's LT77 box !!

But I drove it for over 2 years with it clonking and its still going now, I would have thought that the shaft must be near the end of the spines.

I'll try and find out when the mod' was made and post it.

xsavier · 11-01-2002, 03:52

Sounds, good.

First time this year I switched my lights on... was sure there was not a burning smell before. Dashboard lights gone. :dead:

So I'm off with trusty iron to wreak revenge on the loom

Catch you later,

Neil