Gearbox Removal, Disco 1

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martinl

Active Member
Posts
273
Location
Bilston, West Midlands
Has anyone here tried to get the gearbox out of a Disco from underneath? I've done a classic Rangie in the past with the floor out. Is "floor out" the only option on a Disco. Maybe it could be done if the transfer box was removed first?

Any thoughts?

Thanks all for any input.
 
floor not removeable on a disco so its all done from underneath and all goes down i leave the transferbox on the gearbox and lower it down with an engine crane if you are only doing the clutch then it can be easyer to move the engine forword
 
Hi, Thanks for that, Its my first Disco, bought with no drive so I'm trying to diagnose at the same time. Gearbox all feels as if its selecting but It wont make any engagement with the transfer gears, I've got the bottom cover off and the transfer box seems to engage correctly. now I'm wondering, broken gearbox shaft or clutch, the clutch feels fine from the pedal and nothing is making a noise.

Is it possible to remove the transfer box with the gearbox in situ, just to make it lighter as I'm working alone and with just a trolley jack? Also, I'm thinking maybe to slide the gearbox back still on the crossmember, just to get a hand to the input shaft.

I've done Rangies before and I'm not phazed by the task, just wanted to try and get as much information as possible from others with experience of the Disco. Its good because I was thinking RR and about to remove the seats etc....

Many thanks, Any other input greatly appreciated..
 
Is it possible to remove the transfer box with the gearbox in situ, just to make it lighter as I'm working alone and with just a trolley jack? Also, I'm thinking maybe to slide the gearbox back still on the crossmember, just to get a hand to the input shaft.

both of them will work it could poss be the plastic thrust release bearing, as for the sliding jack box up pull out the gearbox mount you get a good 6 inch sliding back
 
the other thing you can do is take the round plate of the back of the transfer box and see if the shaft in the center is turning i would say that the clutch springs have gone (with a bit of luck it will only need a new clutch) the thing about removing the transferbox is getting it back on its a piging thing to handle its heavy and no flat surface to jack off can be made a bit easyer buy making two long studs that go in the bolt holes at the top to help slide it back on but you still need to be carfull of the oil seal
 
you would be better off lending an engine crane thing. i changed the clutch on my discovery out side the house on the road.
remove propshafts and take out half the bolts on the bell housing, take off gear box mounts disconnect clutch slave cylinder,take out the center console open front door and position engine crane through the open door.

put a chain through the gear stick hole and a strap round the middle of the box, although i found it a lot easier to put a small engine chain pully block on the end of the engine hoist. this way you can control the box while working underneath the vehicle.

lower the gearbox untill you can get the top bell housing bolts and the cable to the reverse switch. remove the top plastic cover on the radiator fan cover so it dont get snagged up when the engine tilts back. stick the jack under the front of the engine to stop it dropping forward when the box is removed.

work the box off the engine making sure it is balanced (makes it easier to handle on your own) slip the box off and use the chain pullies to lower the box as you hold it. it took me two days to remove box, fit clutch and refit the box and i have never done a discovery box before.

the local garage told he it was a b*stard of a job to do and was supprised when i took the clutch aligning tool back and told them i did the job on my own. its an arkward job and the box is very heavy but if you get the strap in a position so the box is perfectly balenced when you lift it back in you will find you are able to move it quite easy and if you use the engine hoist chain pully with the lift chain through the gear stick hole you can lift it and position it on your own quite easily.
its not really as difficult as i was expecting. :D
 
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