Gearbox

Hello all I would appreciate from some sage advice and help please. I have a 200tdi 90 with LT77 gearbox. It has been leaking ATF all over the transfer box for a while and I have had 2 garages so far who said they cannot trace the source. I think it is the gearbox output seal myself.

Anyway yesterday the clutch squeaked a bit on gear change and I lost drive completely in both ranges; diff lock everything.

• I checked the clutch reservoir and it is full so I assume no leak or cylinder fail.
• I can select the gears OK (ie the stick moves into and out of position no problem
• It is not locked up; both axles and propshafts moving freely
• No crunching noises

It just won't move when any gear is selected.

I'm stuck on a few fronts:

1. Don't know what the cause is
2. Do I maybe need a new gearbox and transfer box
3. Is there anyone in a reasonable reach of High Wycombe/South Bucks region garage-wise recommended to repair it?

I know that there is fantastic knowledge available here and I would really appreciate your advice. Many thanks everyone

WW

Will it move in low ratio or with the diff locked?

do any of the props spin when engines running in gear
any changes of noise when you change gear engine running
do both boxes sound like any gears are been driven none or just g box

wireman said:

Will it move in low ratio or with the diff locked?

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No nothing at all!

jamesmartin said:

do any of the props spin when engines running in gear
any changes of noise when you change gear engine running
do both boxes sound like any gears are been driven none or just g box

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No to all of the above thanks. It's is as if no gears are selected at all. But the stick does go into all positions no change of feel.

Wilfred Wood said:

No to all of the above thanks. It's is as if no gears are selected at all. But the stick does go into all positions no change of feel.

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if you cant hear even the g/box turning with engine running it might just be the clutch plate

Is it the main shaft in the gearbox maybe? Clutch seems a bit odd too.

jamesmartin said:

if you cant hear even the g/box turning with engine running it might just be the clutch plate

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Thanks and that might explain the slightly odd clutch feel? I am worried about how the ATF leak may have caused something nasty to happen in the drivetrain though!

Wilfred Wood said:

Is it the main shaft in the gearbox maybe? Clutch seems a bit odd too.

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youd expect to hear some noises nd some feel when changing gears without the clutch been used,though you can check by removing pto cover on t /box

If it is the clutch that has caused this can and do they just 'let go' without any warning or noises? Leading to my symptoms?

Have you checked the bell housing drain to see if there is oil in there, it may have a wading plug in it, oil may be causing the clutch plate to slip.

I've had a clutch plate seperate from its splined center before with no warning.

Flossie said:

I've had a clutch plate seperate from its splined center before with no warning.

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Yes I have too so worth checking,

Europa486 said:

Yes I have too so worth checking,

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Me too, had the same ting happen.

Wilfred Wood said:

If it is the clutch that has caused this can and do they just 'let go' without any warning or noises? Leading to my symptoms?

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yes,if it was your mainshaft splines as is common it would have been clunking for awhile

Scooby22 said:

Have you checked the bell housing drain to see if there is oil in there, it may have a wading plug in it, oil may be causing the clutch plate to slip.

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Thanks yes no plugs in.

Flossie said:

I've had a clutch plate seperate from its splined center before with no warning.

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Thanks - did it make any noises afterwards?

Wilfred Wood said:

Thanks - did it make any noises afterwards?

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I can't remember to be fair, it was a cortina MK2 and was 40yrs ago.

I can answer that one, basically no on a good number of vehicles ( I worked in a garage)
When my series 3 did it likewise sudden no drive also with no noticeable noises but we are talking about
A noisy motor anyway,

if you understand the difference between a spanner a screwdriver and a socket you can get that apart yourself.

Get a manual, and use your phone to take pics each step of the way

Gearbox out is not that difficult, at least you can learn as you go.

If in doubt ask on here, i have learn't loads since owning a variety of vehicles and as my Dad famously quoted to my brother, human hands put it together so human hands can get it apart and rebuild it..

And finally this forum might have lots of banter and laughter and tongue in cheek answers, but the knowledge is phenomenal and whatever problem you have, someone on here will have had it before and when you are in the dire poo, head in your hands stuck,cross, angry or just in tears the members on here always get you back under that vehicle with some positives, some answers and some top tips and occasionally help.

So if in doubt just ask..