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Planning gearbox and clutch replacement need advice


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After completing my last lot of jobs to get the old girl through her MOT, last one being the steering box (heavy and akward but managed it ).

I am now looking at my list of jobs to get done and high on the list is the cam belt which I might tackle myself in the next month and the other is replacing the gearbox and clutch.

In my younger days (in the long distant past) I had the gearbox and transfer box off my old 2A and although it was heavy work and a pain to do alone, I managed it with not too much trouble. However, dont remember having to remove cross members then, I had no carpets or soundproofing or floor to remove (already off) and I also had seat base out as part of refurbishment so access was easy.

Now I no longer have access to a garage and no hoist available. Just a driveway, two axle stands and a 2 ton trolley jack :mellow:

I am now passed my youth and middle age and heading into my twighlight years, the thought of fighting with a gearbox etc is slightly off putting. As I have a lump sum of cash at my disposal soon, so I have decided to get a reconditioned gearbox and get the clutch replaced with a heavy duty version at same time and pay someone to fit it. A bit extravigant I know but worth it for this job.

I have a couple of issues with the gearbox: gear selection (even with new MTF oil), rattle from clutch plate springs during idle and finally an oil leak fairly certain its gearbox or transfer oil but not sure which (too clean for engine oil) coming from wading drain hole (it's not clutch fluid, both master and slave cylinders replaced with new). Not sure if the clutch release arm has been replaced in the past with a reinforced version, so worth getting that done as part of clutch kit !

I have a couple of question's:

1. Of all the recon gearbox suppliers on the internet etc are there any I should avoid and any that members recommend ?

2. Are there any companies who supply and fit recon boxes that can be recommended ? Ideally in the North West area ?

3. Alternatively would I be better just getting an exchange recon gearbox and getting a local Landrover garage to fit it ?

4. Is there anything else worth getting done while my gearbox and clutch are being done ? ie crank output oil seal, bronze bush that takes the input shaft ?

5. I am allowing £600 (+ surcharge for exchange) for a reconditioned box (R380) and around £120 for a heavy duty clutch kit. Any idea what sort of cost should I expect for labour, I am assuming 8 hrs at around £40/hr so £320 to £350 does this sound reasonable ?

I would expect a fully equiped land rover specialist garage should be able to swap a gearbox and refit a clutch in 8 hrs, or am I underestimating ?

Any Feedback, advice and recommendations would be gratefully recieved.

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You might consider a metal clutch release bearing at the same time, the plastic ones are known to melt.

http://www.megasquirt-v8.co.uk/diff_offroad.php - about halfway down the page - the proprietor is a moderator on this forum

If you change the rear crank seal use only a genuine parts seal or you'll be doing the job again fairly soon. To do the rear crank seal you are supposed to remove the flywheel housing, so you will need a gasket for that too

A quick search on lr4x4 will show you that LUK or Valeo are the preferred clutches. Buy a 130 clutch, as these have 8 springs rather than a standard 4 spring one.

http://www.ashcroft-transmissions.co.uk/miscellaneous/clutches/130-tdi-clutch-kit.html

I have no experience of buying a recon gearbox so cannot give you a recommendation, but a lot of people choose Ashcroft Transmissions. I have had numerous aftermarket parts from them and have always received good service

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Thanks for the advice looked on the archive and the picture of the130 clutch plate looks exactly the same as the one I was planning to get in the heavy duty clutch kit ? not sure from picture and no details in description but suspect the release bearing is metal too ! The release fork is definately reinforced. Its not a Valeo suspect its Britpart so that's a bit off putting not many good reviews about there parts. I usually go for Bearmach not been disappointed yet.

As for doing it myself must admit I hate paying garage bills and will tackle almost anything, but having had previous experience taking a box out without a hoist and on my own it doesn't fill me with excitment. Not worth investing in a hoist probably won't use it again and nowhere to store one, I could rent a hoist for a couple of days its cheaper than garage bill ! Its all the internal stripping out I don't like boring and tedious don't mind the actual getting the box off.

I heard you can pull both the boxes back 6 to 8 inches just enough to change the clutch, but fitting the release bearing is tricky. Besides I am 95% sure I am swapping the gearbox for a recon box anyway so the whole lots coming out.

Seems steep but at this stage I woul probably be happier to let a garage do it and pay £400 labour. However, if I get quoted more than that for labour, I may review the situation and get a price for hiring a hoist and do it myself.

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If you are seriously going to buy a Britpart clutch kit then give it some thought before you jump in. Also if the release bearing carrier is metal then check that you can get replacement bearings

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I heard you can pull both the boxes back 6 to 8 inches just enough to change the clutch, but fitting the release bearing is tricky

sliding the release bearing on is easy, even sitting the fork arm & slipper pads isn't hard working through the gap. worst part was realigning the gearbox shaft & engine, some extra long threaded rod to act as guides/supports are worth having, don't let the box hang on the shaft.

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