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PAT303

Member Since: 25 Feb 2013
Location: Australia
Posts: 123

1998 Defender 110 300 Tdi SW Alpine White

Rebuilding the R380

So I found where the gearbox noise was coming from, my R380 finally lunched the 5th bearing after 575,300kms, I'm going to do a rebuild so need to ask what I should replace. Other than bearings and syncro's I was going to do the main and lay shaft, oil pump but what else?. All replies are appreciated Pat

9th Mar 2022 10:59pm

geobloke

Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4395

Hi Pat. My R380 did the same thing, 5th went bye bye.

Done this myself. Before putting your order in (you are a long way from Ashcroft Transmissions) strip the box down and make a list of components. It is not a difficult job, just one that takes time and a few specific tools, press and pullers.

9th Mar 2022 11:03pm

PAT303

Member Since: 25 Feb 2013
Location: Australia
Posts: 123

Thanks mate, I'm going to cut the bearings off, can't be bothered with pullers, the main shaft is not going to be reused anyway. I want to replace everything, the original lasted 24 years and I'm not interested in doing it again.

9th Mar 2022 11:29pm

geobloke

Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4395

The only thing you really need a bearing puller for is the big collar on the output shaft. It is a pain, but not impossible. To get it off I used a large bearing puller and a little heat. Took about 20-30 mins to get off. To get back on again it was the old pipe, bolt and stack of washers method. Worked a treat.

When my 5th gear blew it took made a right mess of the housing, chewed it right up. The suspect was the HD support bearings that had worn incredibly badly providing enough play to skip gear teeth and breaking them.

It was a huge bang whilst cruising on the flat.

The first and only time I have been flat bedded home

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The mess of the bearings, gears and box

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Bearing puller for the collars.

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Good fun this job. Just be super clean when refitting. And if you need inspiration our LR guy at Britannica has just done a 12 part rebuild of a TD5 era R380

https://youtu.be/1cz7ohSLxK8

10th Mar 2022 11:17am

PAT303

Member Since: 25 Feb 2013
Location: Australia
Posts: 123

I will cut the collar off and replace it with a new one, save me the hassle.

10th Mar 2022 2:13pm

Fatboy Slim

Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006

I've done a load of them over the years. You'll struggle to cut the collar off to be honest, because half of it is inside the seal/rear housing.

12th Mar 2022 2:27pm

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