Is this bad or ok for a 1990 200tdi??

Hi all trying to find a bang/clunk when i change gear and take up drive
So looked on this site and came out with spline wear on the gearbox
Now is this bad or ok??sorry about me grunting..live with

Im no expert but i would say that is quite a lot of play.

I drove my land for 7 years knowing there was play in output shaft but never checked how much or bad it was but i could feel it when driving. i would always take up the slack before applying real torque / throttle. knowing that one day it may just strip the splines.

last year my tbox gave up the ghost when swopping over i looked at the splines and say they were about a 3rd gone / worn looking at the amount of movement in the video i would guess yours are a bit worse.

I have since fitted a recon box from ashcroft with cross drilled gears to prevent wear in future .

That's worn,not a lot of time left before it gives up depending on mileage driven per year and how you drive.
It's easy enough to remove the gear and have a proper look.
I recently fitted a new cross drilled gear to a mate's landy,the shaft was worn some but as it does little mileage in a year and everything else was working we though this would extend the life of the gearbox shaft now that it would have some lubrication.
Also the splines in the replacement gear were longer and engaged in a section of shaft that was not worn. Bit of a bodge I know but a year later his landy is still ok and there is no clunk from the drive on take up.

tottot said:

Also the splines in the replacement gear were longer and engaged in a section of shaft that was not worn. Bit of a bodge I know but a year later his landy is still ok and there is no clunk from the drive on take up.

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Ive done exactly that a fair few times now, the longer splines meshing on the unworn bit works well and lasts for 10s of thousands of miles.

Ok but

lynall said:

Ive done exactly that a fair few times now, the longer splines meshing on the unworn bit works well and lasts for 10s of thousands of miles.

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I have a lt77 gearbox...i though it was only on the r380 that had the longer splines???
Thanks

Tbh I cant remember but pretty sure i did the same with my lt77 equipped 90, but it was about 6 years ago now so cant be 100 percent what I actually did, all the others I did the same mod on were as you say 300tdi running R380 boxes.
Iirc the new style gear has the longer splines which meshes with the unworn shaft splines, I can remember some types of early tfer boxes cant have the cross drilled gear fitted as the teeth are narrower?
Makes me feel like an old fart when I cant remember what I have done to my cars!

It was on an LT77 we did change the gear last year and it was a 92 model so you should be ok. As Lynall says only the very early models can not have this mod.

Have to agree Lynall,welcome to the old fart club.But we can still fix them.

Ive been looking it up and found all lt77 mainshafts have short splines
R380 has the long ones
I saw a thread where someone had welded the two together so i though this sounded like a nice cheep fix
Then i looked on ebay and found one that was welded for spears or repair
Eny one done it on here ..if its already fuked and all that ..

Look at this on eBay http://www.ebay.co.uk/itm/262869592292

It's the splines in the replacement cross drilled gear that are longer and engage with an unworn section of the original 77 gear box main shaft.
Do not see what use Ebay item would be to you as it says gear box is foooked.
Gear and shaft could be welded in a dire emergency but you the would not be able to split the box's. Not recommended.

paul grange said:

Ive been looking it up and found all lt77 mainshafts have short splines
R380 has the long ones
I saw a thread where someone had welded the two together so i though this sounded like a nice cheep fix
Then i looked on ebay and found one that was welded for spears or repair
Eny one done it on here ..if its already fuked and all that ..

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Not done the welding one, but can remember a guy on here or another forums who splines were so worn he ground down masonary nails and hammered them in between each spline, then added a washer and a nut on the threaded part of the shaft!
I dont know how long its lasted but you can imagine how thin/worn the splines must have been to get the nails in there?

I reckon the welding might work but you will have to put it in gear and push the car one way or another to make sure the splines take the driving force and not the weld, will be a right bugger in the future should any work need doing.

Safest bet has to be a new gear that way you get rid of half the wear straight away.

What i was saying is i always thought the lt77 has shorter splines that the r380
So if i got a new input gear with the longer splines it would only work on the r380
As there whould be 1/4 unuesd splins
On the lt77 the input gear wears all the splines......
The pick is showing that someone has welded the two together

lynall said:

Not done the welding one, but can remember a guy on here or another forums who splines were so worn he ground down masonary nails and hammered them in between each spline, then added a washer and a nut on the threaded part of the shaft!
I dont know how long its lasted but you can imagine how thin/worn the splines must have been to get the nails in there?

I reckon the welding might work but you will have to put it in gear and push the car one way or another to make sure the splines take the driving force and not the weld, will be a right bugger in the future should any work need doing.

Safest bet has to be a new gear that way you get rid of half the wear straight away.

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Ah thanks for your reply
Im liking the nails idea
Might just last till i can save up for new parts
Bit of a bodge but haho

All the LT77 I've had apart have had 'short' splines, a new gear won't contact an undamaged section. You could fit a new gear anyway, which would remove 50% of the play but you'll still have the weakness of the worn shaft splines.
I will say though, sympathetic driving and use of the clutch will drastically extend the life of these parts!

If I needed a quick fix in your case, I'd simply fit a new cross-drilled gear and go easy with the clutch engagement until I were ready to fit a new gearbox.

David_Cooper said:

All the LT77 I've had apart have had 'short' splines, a new gear won't contact an undamaged section. You could fit a new gear anyway, which would remove 50% of the play but you'll still have the weakness of the worn shaft splines.
I will say though, sympathetic driving and use of the clutch will drastically extend the life of these parts!

If I needed a quick fix in your case, I'd simply fit a new cross-drilled gear and go easy with the clutch engagement until I were ready to fit a new gearbox.

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David what we were saying above is for some of the lt77 you cant get the cross drilled gear, new gear yes but not the essential cross drilling.

This is true, but I thought that was only the very early/ to mid 80s transfer boxes, suffix A and B? You can fit the splash plate to the early ones.
What I find most amazing is that it took LR until 1996 to fix the problem!

Thanks guys
Im getting married in 3 weeks and my landys going to b the bridal car
Last thing i need is no drive half way there lol
Im guna take out the gear then take a pick of the splines c if the needle thin or half way through there life ....

David_Cooper said:

This is true, but I thought that was only the very early/ to mid 80s transfer boxes, suffix A and B? You can fit the splash plate to the early ones.
What I find most amazing is that it took LR until 1996 to fix the problem!

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Im not sure on suffix numbers but when I got my 90 it had an early r/r tfer box in it with a 1.19 ratio and I couldnt get a cross drilled gear for it, I was running tall tyres so went back to a 1.4 box cant remember what year or gear its got but its still working so far!