I ordered a clutch oil seal the other day with some other bits for the gearbox change on my 300tdi defender. Now having removed the flywheel to expose the original oil seal, there is tiny bit of oil made its way past but nothing bad by any means. This is a uk made part which makes me think it...

Given the difference in materials and grain structures, I wasn't sure how well they would stick together. I have no concern now but until you try it you never know. I don't want to be worrying whether the extension will break off, come loose or generally move in any way. I like doing things once...

I was a little concerned about welding to a forging, but even with it tacked on it was rock solid, there is a lot more weld underneath where the forging spreads out. With the heat turned up there is no way that is going anywhere.

Personally I'd just change the shaft as well, but without the appropriate tools I'd have to pay someone to do the work. As its an unknown box bought in good faith I wanted to keep things cheap. if it is knackered I'll just rebuild my defender one.

Unfortunately I never throw anything away! I think that will be a good box with new 5th gear again and complete rebuild. It wasn't crunchy before.

I think 5th gear is slightly worn! all sorts of bearing material and the other half of this tooth came out in the oil. Bit of a mess really. Just as well I have nice low milage disco box to fit. I think what has happened is as the clearances have increased as the bearings have worn the gears...

I'll report on how it works in the vehicle after the weekend once its fitted.

This may help illustrate to everyone what is involved in converting a disco gearbox to fit a defender, its really easy, just time consuming to ensure a tight fit and accurate alignment. I cut off the rear part of the discovery selector to retain the part that fits onto the shaft, then just...

Well yes. I may calculate it properly later on for the 2 transfer boxes if I can find the gear ratios for the main box. That way it will be accurate for my tyre size too.

In 5th gear what is the difference in revs at 60mph between the two boxes?

Thanks for the tip I'll investigate that bearing, assuming I do still have an original box (doubtful) Its still in pretty good shape at 146k. While its apart I shall change the flywheel sprigot bush, clutch arm for a heavy duty one and crankshaft oil seal. I did the clutch 8k miles ago so...

Oh yes, at low speed in 4th and 5th its a loud drumming vibration not a general vibration.

Infact, there is a slight noisy bering noise from the gearbox when cold in neutral. , and and a sound like a few marbles have been let loose on top of the gearbox when driving along, which could lean towards input bearings then. I think if I go as far as removing the gearbox I will just fit...

I have been battling today to change the transfer box on my defender in the hope that that will cure a vibration below about 45 mph in 4th and 5th, though there is vibration in 3rd at slow speed, which led me to think maybe it was the transfer box at fault. Edit: tried the usual tricks to cure...

I think the issue with tdi's is that while they are nice and simple, most of them have done a lot of miles and even the youngest is 14 years old so you will pick up all the inevitable old car issues, rust dodgy seals etc. while the engine may run and run the rest of it may be falling apart...

Don't tell them, they make life so difficult these days its not worth the effort.

Morning all. My power steering pump in the space of 100 miles has started making some very unpleasant noises, so is rapidly disintegrating, if anyone has one spare that would be appreciated. If I've got to slacken the serpentine belt I would also like to replace the alternator as thats not...

This is still an ongoing project. I want to take the selector remote off my box and the quadrant to get some proper measurements, in order to get the selector quadrant really tight on the shaft, nothing worse then a poorly fitting shaft!

Making an adaptor to elongate the selector shaft to allow the defender remote to fit the disco box. Assuming were talking r380. search defender to disco or something like that as theres a diagram of the adaptor you need. Can't confirm it works yet as I'm still making the adaptor.

I would also be interested in a defender selector shaft If anyone has a complete buggered r380 they don't need that I could be interested in it for these parts. Thanks