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alexatnd



Member Since: 19 May 2015
Location: Yorkshire
Posts: 292

United Kingdom 
TD5 gearbox replacement - at home -
Hi all
At some point I'm going to have to get my R3780 refurbished. Working at home, got an engine hoist but thats it. Was wondering,if I am better off doing things in bits i.e.
remove xfer box
remove r380
leave bell housing in place.

looking at the sixe of xfer and gear boxes loooks as if they might be more managable individually, although guess the issues might arise when putting them back in. instead of taking them out
A Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - new chassis etc back on road
Effie - 2004 110 TD5 County
Post #1071745 19th Jul 2025 6:30pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17876

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
You cannot leave the bellhousing in place, it can only be removed from the box once the box is off the car.

It is significantly easier to remove the transfer box first, then the gearbox. Both are heavy and I recommend buying/borrowing/hiring a gearbox jack, although some people use an engine hoist through the door of the cab.

It is actually not a difficult job to do at home on the drive with basic equipment, but the boxes are heavy enough to require care.
Post #1071747 19th Jul 2025 6:48pm
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miker



Member Since: 13 Sep 2015
Location: Surrey
Posts: 1784

United Kingdom 1999 Defender 110 Td5 CSW Rioja Red
Miserable but achievable, I've done it with both engine hoist and trolley jack. Have always pulled them separately

Made an adapter for the trolley jack to pickup on the slanted face of the transfer box.
Post #1071756 19th Jul 2025 9:39pm
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300TDi CSW Phil



Member Since: 03 Apr 2016
Location: Bracknell
Posts: 815

United Kingdom 1995 Defender 110 300 Tdi CSW Epsom Green
Did the two combined when I had to replace all the clutch components. Never again, next time it is coming out as two separate parts. 1995 300 Tdi Epsom Green- Slowly Turning into Keswick Green - It's a keeper.
Wide Track Sankey- In bits- Gone to a new home
M0XQS
Post #1071760 19th Jul 2025 10:09pm
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tony.g



Member Since: 25 Aug 2017
Location: uk
Posts: 23

When putting the transfer box back onto the gearbox, it helps if you can get a set of hardened steel guide pins. These keep the t/box square and avoids damaging the oil seal.
Some use lengths of threaded bar.
Post #1071763 19th Jul 2025 11:05pm
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paul 123



Member Since: 10 Jul 2022
Location: norwich
Posts: 134

United Kingdom 1995 Defender 90 300 Tdi HT Auto Rutland Red
long bolts work better than threaded bar as the transfer box can bite onto the threads making it hard to slide on. with cutdown bolts put a little oil on them to help it slide into position. the threads are iirc m10.
Post #1071769 20th Jul 2025 5:47am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17876

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
tony.g wrote:
When putting the transfer box back onto the gearbox, it helps if you can get a set of hardened steel guide pins. These keep the t/box square and avoids damaging the oil seal.
Some use lengths of threaded bar.


They don't need to be hardened (why on earth would they?), normal bolts with the heads cut off and with a slot for a screwdriver cut in work perfectly and replicate the genuine tool. As I recall you need M10 x 175mm, a minimum of two but three is better.
Post #1071773 20th Jul 2025 8:15am
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MadTom



Member Since: 10 Sep 2013
Location: Olomouc
Posts: 672

Czech Republic 1999 Defender 130 Td5 HCPU Baltic Blue
When I hat to replace clutch on our Disco2 TD5 I had removed gearbox and transfer box together. I have used big pipe placed on two stands through opened front doors and a rope puller to lift and lower the combo home for gearstick. Car was placed on 10cm high blocks of wood and combo was lowered on a steel plate on the ground, to pull be able to pull it out. "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo Smile
Post #1071819 20th Jul 2025 6:58pm
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julian



Member Since: 17 Feb 2017
Location: Devon
Posts: 183

United Kingdom 1994 Defender 110 300 Tdi CSW Alpine White
I think anyone who does lt230 boxes in any number has a custom jack head.

I did not.

It's heavy and doesn't sit flat on anything. We used ratchet straps bodged off bits of wood, up above in the body.


I've got (unfitted) one of those high cap oil cooler things. I will certainly fit that before ever removing the lt230 again, as just having one flat on the bottom of it must make it a whole load easier.
Post #1071838 20th Jul 2025 10:04pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17876

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
There is a special tool available to get round this problem, although the price will put many people off. Combined with a decent transmission jack it makes the task relatively easy, and it is not difficult to make an equivalent. It can be made from wood if easier.

https://jlrequipment.service-solutions.com/ItemDetail?SKU=100-045
Post #1071842 20th Jul 2025 10:46pm
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Penfold_6290



Member Since: 22 Sep 2021
Location: Dorset
Posts: 387

United Kingdom 2002 Defender 110 Td5 CSW Epsom Green
I've done the job three times on a couple of Defenders and each time I have kept the gearbox and transfer box together as one unit. It's physically demanding and I doubt I'll ever want to do it again! I used an engine hoist through the passenger door. Using ratchet straps front and back to adjust the pitch if needs be. I like the idea of beheaded bolts as guide pins because getting the box close is not an issue, getting it right is a massive PITA! Having some guide pins to get your aim right for the final 6 inches would help immensely.

And whatever you do make you sure you don't forget to unplug the crankshaft position sensor...ask me how I know.
Post #1071877 21st Jul 2025 11:07am
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Procta



Member Since: 04 Dec 2016
Location: Sunderland
Posts: 5326

United Kingdom 
Me and my dad did a clutch job twice on his defender, Second time i bought a large jack, and he listened to me this time.
1st time, the fool had the car on the ramps, which made it a bloody nightmare all round. Wincing the bloody box in place with straps from the roof!
2nd time i said leave all four wheels on the ground, He wasn't happy, but made life a lot easier with the large jack to help. We should have removed the transfer box, but my dad didn't want to disturb anything more. Funny thing was it didn't even need doing in the 1st place, and burnt the replacement clutch out, by not adjusting the clutch pedal, again not listening. Defender TD5 90 ---/--- Peugeot 306 HDI hatch back

In the words of my Good Friend, Gary Forrest 1980 -2025
" we will work something out"
Post #1072144 24th Jul 2025 9:36pm
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revd



Member Since: 20 Apr 2024
Location: England
Posts: 272

United Kingdom 
^
‘to you, to me’

(aka The Chuckle Brothers)
Post #1072164 25th Jul 2025 8:45am
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jonny



Member Since: 10 Mar 2013
Location: North Wilts
Posts: 209

Penfold_6290 wrote:
Having some guide pins to get your aim right for the final 6 inches would help immensely.


It also lines everything up square so you don't snag the transfer box seal as it slides together. There is no worse sensation than putting everything back together, taking it for a quick test drive then seeing EP90 pool underneath and realising you have to do it all over again because you have b0rked the seal...
Post #1072168 25th Jul 2025 9:17am
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34064



Member Since: 12 Dec 2023
Location: South Central
Posts: 229

United Kingdom 2003 Defender 110 Td5 HT Alaska White
I have done this multiple times on my back on the drive both on Discovery's and my defender. It is easier to put a engine crane through the door and lift the whole lot out as one so Transfer box gear box bell housing then it is trying to line up the transfer box back onto the gear box as the seal for the transfer box input is very venerable. I tend to jack the car up a bare minimum to get the shafts off and work upstairs stripping the interior then going downstairs to finish it all off getting split i have removed one on my own but two people is ideal and going back in this way two is a minimum its all do able but you'll ache for a few days afterwards. 110 Td5 Ex Utilities slowly converting into a pop top camper one day

Build thread:https://www.defender2.net/forum/post1024784.html#1024784
Post #1072173 25th Jul 2025 10:18am
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