Gearbox Woes on Td5 Manual

[Big Mike]

I have began recently having trouble with my Series 2 Discovery gearbox. When it goes on a run, decent run that is, talking 20 miles or more, the gear selector goes stiff on it in the neutral position. It is a manual 5 speed transmission, the trouble seems to lie in the neutral position, and when changing gears I have to help the gearstick find its way into the next gear that natural return to middle position is gone. It is particularly bad when changing down out of 5th gear I find. Its a 52 plate Disco, and it is low milage, not even 25,000 on the clock! When the eeverything is cold it works fine, but once its been running continuously for 20/25 miles, it starts to stiffen up. Then when it cools down, its great again.

Out of point, the trouble is occuring in high range, I have not even tried low range gears on it as since the trouble started I was worried I'd never get it back out of low range again. Besides, lately, I won't be making much use of low range gears so it doesn't really matter I think. As it will be holidays and trekking all over the UK. Or so I hope!

I was wondering if anybody knew waht the fault is, because I heard it affected the Discovery 1 gearboxes too something about a washer on it breaking causing the trouble, also, out of curiosity, do Disco 2's and Disco 1's make use of the same gearbox?

I think, I ought to mention what I have done, when I discovered the gear problem, it was on a run from Swansea to Camarthen, which is about 50 miles or so round trip. When I returned home I crawled underneath the car, and touched the gearbox, it was actually hotter than the exhaust, and I thought to myself that is never right.

I am reluctant to make use of the Land Rover dealer in Swansea as since the new management came I have had a couple of bad experiences with them and the work they do seems very temporary at best, to put it politely. I took it to a local garage in the town I live he is a 4x4 specialist, he changed the oil in the gearbox and filled it with the recommended oil as set by Land Rover themselves. This did yield a small improvement when I took it on another little run, it was still stiff but more manageable than before.

I am going on a trip to Warwickshire, probably tomorrow, and I am thinking of taking the Discovery up, chancing the trip and booking it in with one of the Guy Salmon dealers there. As gearboxes are a big job I am aware of that, I just hoped from what I have put here, somebody has any incling as to what this could be, so I am at least up to speed with what is going on.

Thanking in advance.

[thermidorthelobster]

200tdi Discos used the LT77 gearbox which was prone to stripping the input shaft splines.  300tdis and TD5s use the R380 gearbox.  This is generally a fairly reliable box, although synchromesh in 2nd tends to be a bit iffy, and occasionally 3rd.

I've not come across your problem before.  The most obvious thing I can think of is the wrong oil has been put in, or the wrong amount, so I'd start with an oil change.  Don't assume that because it's been done by somebody who is supposed to know what they're doing, it's right;  a friend of mine had an LT95 wrecked TWICE because 2 different "dealers" put in the wrong oil, and the second one used too much of it to boot.  (The LT95 gearbox takes engine oil, and EP90 is way too thin for it.)  The people who look after my DII use a semi-synthetic oil, from memory, but I'd have to check exactly what it is, because I normally leave it to them to change it when it's being serviced.

The only other thing I can think of is maybe a shim or washer or something is breaking up, and when the gearbox is heating up, thermal expansion is causing things to solidify a bit.  It's not unusual for an R380 to get hot in use, but you shouldn't be able to fry an egg on it.

[Big Mike]

Hi Lobster,

Thanks for the reply. I suspected the gearbox on the Disco 2 was the same as on the Disco 1.

Because you have the Disco 1 200 Tdi, then the Disco 1 (updated) with the 300Tdi. Then the Disco 2 followed by the Disco 2 Facelift. Sorry for stating the obvious, but this is my first ever 4x4.

A friend of mine, who used to work for for the dealer prior to new management, said he thought it could have been what you said right at the bottom of the post. In any case, the oil was changed and he told me he put the recommended gearbox oil in that Land Rover recommended, and it made a difference, a big difference but the problem is still there.

Can I just ask, hypothetically assuming it is a broken washer or shim or something else thats broke to bits in there, when work on the gearbox is carried out to remedy the problem, how long is it likely to take to finish work?

[thermidorthelobster]

You're right about the models.  The only thing I'd add is that the facelift TD5 was just that, they didn't change much at all apart from the front end, engine ECU mappings and some interior trim stuff.

Taking the gearbox out is a few hours' work if you have the right facilities, so you're probably looking at a day or so if they have to repair it, more if they have to replace it with a recon box.  I'd strongly recommend you ring Ashcrofts and ask them what they think;  if the box turns out to be shot then they'll probably be your best bet for a recon replacement anyway.

Personally I'd find a good independent (who has the right diagnostics hardware for a Disco II) and not trust it to the main dealer, who will charge you a lot more and take a lot more time to work it out, but you have to make do with whatever you have around!

From what you've said I'm thinking maybe the wrong oil was in there prior to your recent oil change, and some damage has been done which is lessened with the right oil but you still have the underlying problem.

[Big Mike]

Looks like I will have to go with a main dealer, there is nowhere local to me with the necessary kit on hand to work on it, believe me I thought about it. So I am pretty much stumped. Got no choice on the subject.

I suppose a main dealer will be charging upwards of £400 for it? Am I close? That's if the gearbox is repairable, which I think it is. As its still perfectly drivable and engages in and out of gear easily enough, its just the neutral selection. Well, I'll arrange a booking and a quote as soon as poss. Tuesday after bank holiday it is.

[Xtremeteam]

Looks like I will have to go with a main dealer, there is nowhere local to me with the necessary kit on hand to work on it, believe me I thought about it. So I am pretty much stumped. Got no choice on the subject.

I suppose a main dealer will be charging upwards of £400 for it? Am I close? That's if the gearbox is repairable, which I think it is. As its still perfectly drivable and engages in and out of gear easily enough, its just the neutral selection. Well, I'll arrange a booking and a quote as soon as poss. Tuesday after bank holiday it is.

If you get a main dealer to do it taking the box out is gonna be 7 hours x £50 an hour atleast,
Recon box is £550 ish,new outright is over 800,
In the middle of sorting out the logistics & cost for a mates 110 thats a TD5 that the box went sour,got a box & Tbox for his TD5 110 from a breaker for sub 300 delivered

[thermidorthelobster]

It's still worth giving Ashcrofts a ring for advice.  If it's even a vaguely common fault they'll be able to tell you what it is and you'll have an idea of what sort of repair you're looking at;  that way, when the main stealer tells you the whole gearbox needs replacing and it'll cost three grand, you'll be in a position to point them in the direction of the 50p washer or whatever it is.

[Big Mike]

Just been to the website got the number, will ring Ashcrofts first for sure before going anywhere.

thanks muchly for the input gentlemen. Will let you know how it turns out in a week.