Defender 200tdi LT77 noise and rebuild

Skolmate · Jul 18, 2024

Hi Guys,
1991 Defenderc110 200tdi with Lt77 gearbox. I've got a chatter in any gear when a depress the clutch. When shifting down this happens mainly and 3rd is by far the trickiest to find or loudest chatter, again mainly when shifting down.

I can be sat at a roundabout in 2nd with clutch down and it starts to chatter sometimes.
I'm told it could be either the clutch release bearing but probably the synchros wearing.

I have started towing in the last 3 months so perhaps related.
I've done a full flush of the box which has made no difference but old wild looked pretty sad.

I'm told a box rebuild would be the best option as I have looked at the stumpy r380 option also but cost and mods seem unrealistic right now.

If I go for the rebuild, a seem to remember but not completely something about getting an uprated bored shaft for the oil to pass through, could anyone help elaborate on this poor description please.

As always much appreciated in advance for any help.

shaynecm · Jul 18, 2024

If i were you I woud give Ashcrofts a call and get advice on gearbox.
and speak to Luke at LOF about Clutch side.

lynall · Jul 18, 2024

Lightly lift clutch, if rattle goes away then suspect release bearing.

You need the cross drilled gear, but some lt77 input gears cannot be had cross drilled, 26/27 teeth rings a bell?

Dod you know the lt77 has a mesh filter that you can access and clean? this will give you a good idea how bad/good the gearbox internals are.

Skolmate · Jul 18, 2024

lynall said:
Lightly lift clutch, if rattle goes away then suspect release bearing.

You need the cross drilled gear, but some lt77 input gears cannot be had cross drilled, 26/27 teeth rings a bell?

Dod you know the lt77 has a mesh filter that you can access and clean? this will give you a good idea how bad/good the gearbox internals are.

Thanks pal, yes the cross drill gear is what I was thinking about.
Yes I've checked the mesh and magnet checked what came out, not too bad apart from 1 little bit of metal. I'll try and attach the photo.

lynall · Jul 18, 2024

Skolmate said:
Thanks pal, yes the cross drill gear is what I was thinking about.
Yes I've checked the mesh and magnet checked what came out, not too bad apart from 1 little bit of metal. I'll try and attach the photo.

I would be pleased with that filter, I am sure years ago mine had swarf and all sorts of crap on it, still have the car now.

Skolmate · Jul 18, 2024

lynall said:
I would be pleased with that filter, I am sure years ago mine had swarf and all sorts of crap on it, still have the car now.

Zoom in onto the cloth and you'll see the shard

Skolmate · Jul 19, 2024

lynall said:
Lightly lift clutch, if rattle goes away then suspect release bearing.

You need the cross drilled gear, but some lt77 input gears cannot be had cross drilled, 26/27 teeth rings a bell?

Dod you know the lt77 has a mesh filter that you can access and clean? this will give you a good idea how bad/good the gearbox internals are.

So when I loft the clutch slightly the rattle does go away.

lynall · Jul 20, 2024

Skolmate said:
So when I loft the clutch slightly the rattle does go away.

well that would normally point to release bearing or the damper springs in the clutch plate breaking up

dag019 · Jul 20, 2024

Skolmate said:
I'm told a box rebuild would be the best option as I have looked at the stumpy r380 option also but cost and mods seem unrealistic right now.

I have just removed my lt77 gearbox and had it rebuilt by Ashcroft (£645 +vat). I dropped it off on Tuesday, collected it the following Thursday, I was very happy with a 9 day turn around. Unfortunately life conspired against me yesterday so have not completed refitting it for my trip to scotland today which has been cancelled and instead will be refitting gear linkage and floor panels!

I have a thread the removal process: LINK

I also have a thread discussing the merits of fitting the stumpy r380 vs the lt77: LINK Although this thread has not really answered the question and due to time reasons I just got the lt77 rebuilt this time around. I will continue to look into this ads an option for next time as I am likely to be due another rebuild in 3-4 years. One thing I do know form speaking to Ashcroft is there is no modification needed for fitting the r380 stumpy. It is a straight swap, but you do need the later diff lock lever which Ashcroft can supply.

Skolmate · Jul 21, 2024

lynall said:
well that would normally point to release bearing or the damper springs in the clutch plate breaking up

So maybe it's the clutch after all.

Skolmate · Jul 21, 2024

dag019 said:
I have just removed my lt77 gearbox and had it rebuilt by Ashcroft (£645 +vat). I dropped it off on Tuesday, collected it the following Thursday, I was very happy with a 9 day turn around. Unfortunately life conspired against me yesterday so have not completed refitting it for my trip to scotland today which has been cancelled and instead will be refitting gear linkage and floor panels!

I have a thread the removal process: LINK

I also have a thread discussing the merits of fitting the stumpy r380 vs the lt77: LINK Although this thread has not really answered the question and due to time reasons I just got the lt77 rebuilt this time around. I will continue to look into this ads an option for next time as I am likely to be due another rebuild in 3-4 years. One thing I do know form speaking to Ashcroft is there is no modification needed for fitting the r380 stumpy. It is a straight swap, but you do need the later diff lock lever which Ashcroft can supply.

Great thank you. Will the tunnel not need adjusting?

Skolmate · Jul 21, 2024

dag019 said:
I have just removed my lt77 gearbox and had it rebuilt by Ashcroft (£645 +vat). I dropped it off on Tuesday, collected it the following Thursday, I was very happy with a 9 day turn around. Unfortunately life conspired against me yesterday so have not completed refitting it for my trip to scotland today which has been cancelled and instead will be refitting gear linkage and floor panels!

I have a thread the removal process: LINK

I also have a thread discussing the merits of fitting the stumpy r380 vs the lt77: LINK Although this thread has not really answered the question and due to time reasons I just got the lt77 rebuilt this time around. I will continue to look into this ads an option for next time as I am likely to be due another rebuild in 3-4 years. One thing I do know form speaking to Ashcroft is there is no modification needed for fitting the r380 stumpy. It is a straight swap, but you do need the later diff lock lever which Ashcroft can supply.

I read your post the other day, great post buddy

Skolmate · Jul 22, 2024

shaynecm said:
If i were you I woud give Ashcrofts a call and get advice on gearbox.
and speak to Luke at LOF about Clutch side.

Spoke with Luke, was a great help. Thanks, pal.
Sounds like it might be the spigot bush

dag019 · Jul 23, 2024

Skolmate said:
Great thank you. Will the tunnel not need adjusting?

Not according to Ashcroft. It is a direct swap. Which is what Land Rover designed it for for warranty replacements of an lt77. I need to check but am fairly sure even the salve is on the same side as the lt77 (opposite on an r380). All you require additionally is the difflock lever.

Defender 200tdi LT77 noise and rebuild

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