Disco 2 380 gearbox rebuild

I bought a disco 2 from a cowboy, the gearbox is shot, whining big style, drained it to check only a cup full of oil in the transfer box, long story short guy said a backstreet company he uses put another gearbox in but obviously never checked the oil, total bull****ter, done some research turns out it was stolen recovered, he got a disco 3 to replace it and sold it on, anyway **** happens, I have bought a rebuild kit (bearings) only, had a look at my haynes manual which was not too help full, pointers appreciated.

have you got access to a press or have long legged pullers

Yes pullers, should invest in or build a press right enough

jamesmartin said:

have you got access to a press or have long legged pullers

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Fairly new to the board, may have put reply in new post,anyway,yes can get pullers from the work,should build myself a press.

i can tell you how rebuild one but it would have to be on the phone

or you could get James to do it for you

WHY not on here James??

jamesmartin said:

i can tell you how rebuild one but it would have to be on the phone

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Sounds extremely unlikely, I could afford to stay on a phone for the amount of time required, but although a nice gesture, I was hoping for directions to a rebuild site/manual, to view or purchase, but being a good maintenance engineer, i suppose like everything else, i will just do it, cheers.

Magicgrotto said:

WHY not on here James??

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its a fairly big thing to write down,and its easier if a novice has the box and tools in front of them

Might be worth posting up how I got on, when I get started.

jamesmartin said:

its a fairly big thing to write down,and its easier if a novice has the box and tools in front of them

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I see where u are coming from james, I would not like to take your time up on the phone.

Ian Mackay said:

Sounds extremely unlikely, I could afford to stay on a phone for the amount of time required, but although a nice gesture, I was hoping for directions to a rebuild site/manual, to view or purchase, but being a good maintenance engineer, i suppose like everything else, i will just do it, cheers.

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i wasnt suggesting your on the phone for several hours , a few 5 minute calls usually does it but anyhow
try thishttps://www.google.co.uk/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&cad=rja&uact=8&ved=0ahUKEwjU_Ifiz8LRAhUCOsAKHV3fA6EQFggbMAA&url=http%3A%2F%2Fwww.landroverresource.com%2Fdocs%2FR380_Gearbox_Overhaul_Manual.pdf&usg=AFQjCNHsQGi_PtpsLR208-GC-18MaYJSPg

jamesmartin said:

i wasnt suggesting your on the phone for several hours , a few 5 minute calls usually does it but anyhow
try thishttps://www.google.co.uk/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&cad=rja&uact=8&ved=0ahUKEwjU_Ifiz8LRAhUCOsAKHV3fA6EQFggbMAA&url=http%3A%2F%2Fwww.landroverresource.com%2Fdocs%2FR380_Gearbox_Overhaul_Manual.pdf&usg=AFQjCNHsQGi_PtpsLR208-GC-18MaYJSPg

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Thanks James, will check it out shortly, I thought it may have been a bit more involved than a few calls there are many bearings supplied for the box, i believe there may be worn syncros, did i pick up somewhere that there was an internal oil pump/filter and so on, lots of interesting stuff to get my head round,

Thanks again james, just had a quick look, 40 pages alone for the gearbox, will need to clean my welding table and as always pay attention to detail, anything similar for the transfer box ?

great saved both of these, wish i was retired, so much to do so little time lol

you will need a 32mm socket deep if possible , 10mm bihex socket thin wall, 10mm single hex socket plus 6 inch extension, external circlip pliers ,5mm allen socket, and maybe 6mm allen socket depending on which top 2 internal extension case to box bolts are used, drain plug is 1,1/4 or 32mm, filler t55 torx bit, 15mm 1/2 single hex socket and extensions for bell housing bolts,and a copper hammer is very useful

cheers James, got all of the above,

Just a knock on from the gearbox thread, I was talking to a chap today who's mate is breaking 300 Tdi I think it's the same box as the Tdi can you confirm before I buy

td5 has a different input shaft, you can only swap a td5 shaft to a 300 box if both boxes have the same suffix ie both j or both l or k