P38 2.5DT Manual Gearbox Issues

Hi
I have recently purchased a 1996 2.5DT Diesel P38.

I knew it was a no-runner when I bought it but it was such a bargain, with only 112k on the clock and a full 12mth MOT. The seller had it in the garage for 12mths as it needed a gearbox replacement. Which he undertook in April this year and whilst the gearbox was out he fitted a new clutch fitted, new spigot bearing, new roll pins, new front pads. It's also had a new battery, and has coil springs instead of the airbag suspension system.

However, he was driving it the other week and then bang. He suspects it was the selector box and sure enough when my mechanic took it apart the selector pin had sheared. I bought a new pin last week and my mechanic fitted it. BUT when he put it all back together again (or connect the gear stick), it would not shift into any gears at all and appears to be 'jammed' in gear and solid.

I suspect that I will probably need to have a new gear box fitted and was after all the above description, my question is really, is this a job that can be done with the car on ramps in my back yard (have seen one for sale on ebay for £185 + £65 postage/delivery) or will I have to have it "recovered" to the nearest garage and get them to do it? (I have a specialist Land Rover mechanic about 10miles from home) You see I am getting mixed responses to the question. Some people are saying it needs to be up on a ramp and it will take x number of people to drop the old box out and install the new, others are saying no it can be done where the vehicle is.

The other question is could it actually be something else and not the gearbox?

It's worth me getting the car done as I said because it is immaculate throughout with no rust, dents or scratches.

Any advice would be gratefully received and taken into consideration.

Thanks in advance

Sue

The box can probably be dropped at home on ramps although you will be limited for height.....so if you can boost the vehicle higher that will help considerably.

The box with the transfer box attached is quite heavy and will require two to stabilise and then use a jack with a makeshift cradle to lower...but again, you are limited for height when using a jack.

If you are handy with a spanner, it is a DIY-able job....but again, height is the limiting factor.....I have seen ramps with integrated bottle jacks that can give you additional height when required!

Thanks for that Saint, very useful information.

Easy job to do, Get the car on four ramps, take the transfer box off the gearbox then remove the gearbox. The only difficult bit is getting the t/box back on because of the weight distribution. I have done it on my back, without ramps or trolley jack but I wouldn't recommend this method to anyone. I had broken down in the middle of France so need's must. I must be getting old as I bought a transmission adapter plate for my trolley jack a few weeks ago , should make the removal/refitting easier. Item number300967531298 The Bay of E £29.99 free p&p

tomcat59alan said:

Easy job to do, Get the car on four ramps, take the transfer box off the gearbox then remove the gearbox. The only difficult bit is getting the t/box back on because of the weight distribution. I have done it on my back, without ramps or trolley jack but I wouldn't recommend this method to anyone. I had broken down in the middle of France so need's must. I must be getting old as I bought a transmission adapter plate for my trolley jack a few weeks ago , should make the removal/refitting easier. Item number300967531298 The Bay of E £29.99 free p&p

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I wouldn't say easy! I left the transfer box on, admittedly, but it weighed a ton. Getting it off wasn't too bad but getting the shaft lined back up on reassembly was a bit of a sod and that was using a 4 poster ramp. I've seen people do it in car-park's so I know it is possible but you need lorry straps or some muscle to tease it back in.

@jamesmartin might know if it is something simple and whether you have to take the whole box off again or if you can maybe drop the back down and fiddle from above.

engine crane with a chain or sling through the tunnel is easiest,box will need lowering on a jack (mounts and cross member removed but still connected to the engine)first to remove the tunnel plate and if you want to work on the selector housing, id remove the housing first and check its fitted to yoke in box correctly and it works if removed, its possible to pull the box selector rail between 2 selector forks if so box would need pulling apart to reset

Grrrrrr said:

I wouldn't say easy! I left the transfer box on, admittedly, but it weighed a ton. Getting it off wasn't too bad but getting the shaft lined back up on reassembly was a bit of a sod and that was using a 4 poster ramp. I've seen people do it in car-park's so I know it is possible but you need lorry straps or some muscle to tease it back in.

@jamesmartin might know if it is something simple and whether you have to take the whole box off again or if you can maybe drop the back down and fiddle from above.

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Try it without the t/box it's easier,the t/box weigh's 112lb's, I know because I had to side bench press it onto my stomach then lift and push forward to get the shaft entered.No ratchet straps just muscle. To be quite clear, we do not want to know where you go dogging to see people doing it in a car park.

jamesmartin said:

engine crane with a chain or sling through the tunnel is easiest,box will need lowering on a jack (mounts and cross member removed but still connected to the engine)first to remove the tunnel plate and if you want to work on the selector housing, id remove the housing first and check its fitted to yoke in box correctly and it works if removed, its possible to pull the box selector rail between 2 selector forks if so box would need pulling apart to reset

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Sounds like the selector pin is in the wrong place.

.possibly

jamesmartin said:

.

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Is that all you have to say Martin?

tomcat59alan said:

Is that all you have to say Martin?

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He's a man of few words but makes sure they count when he does use them.

Did mine in the drive with out ramps just put on high and stands under chassis ,two can do it with trolly jacks just split box and transfer leave clutch and bell housing on engine to make it easyier to line it up gearbox get some one to push the clutch down on the last bit.

This is a motorbike jack but works well with heavy box, wood leaves the box in perfect alignment for an easier job.

That's what I used as well as a big trolley jack , the motorcycle lift was great for the transfer box we had lump of old work top and a couple of bricks and it put box in perfect possition

brianp38dse said:

That's what I used as well as a big trolley jack , the motorcycle lift was great for the transfer box we had lump of old work top and a couple of bricks and it put box in perfect possition

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Proper engineering then Brian.

Mine was all screwed together, if it has to come out again, wood on jack and away we go again and again.

Gmacz said:

Mine was all screwed together, if it has to come out again, wood on jack and away we go again and again.

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Where did you get the musician smilies? I can only get boring crap.

http://www.clicksmilies.com/
Hundreds of them, RR forum is about to get more colourful.

Gmacz said:

http://www.clicksmilies.com/
Hundreds of them, RR forum is about to get more colourful.

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And not before time.

Gmacz said:

http://www.clicksmilies.com/
Hundreds of them, RR forum is about to get more colourful.

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FFS. What have you done?!