WillFind Posted December 12, 2018 Share Posted December 12, 2018 Background - I have a 1989 defender 2.5td which at some point in the past (i think about 2000) was converted to a 200tdi with LT77 gearbox. The LT77 and LT230 are now showing their age and the splines at the input gear are very worn. I also have an R380 gearbox and transfer case from a td5 discovery 2 (with diff lock) which are in very good condition. The question - 1. Will the discovery r380 bell housing bolt up to the back of the 200tdi? I know that this the r380 is 30mm longer than the lt77 and that ashcroft make a stumpy bellhousing kit for mounting the r380 to 200tdi but it is expensive and currently not in stock!! My thoughts being that if the r380 gearbox with the long bellhousing can bolt strait into the 200tdi i would just move the engine and gearbox mounts foreward by 30mm and thus save myself some money. Quote Link to comment Share on other sites More sharing options...
Tim2809 Posted December 12, 2018 Share Posted December 12, 2018 dont think a td5 r380 imput shaft is correct length even if you had a 300. Quote Link to comment Share on other sites More sharing options...
Retroanaconda Posted December 12, 2018 Share Posted December 12, 2018 The gearbox is only 30mm longer but the R380 bellhousing is significantly longer than the short LT77 one as used in your Defender. As such you would have to move the engine about 5-6” forward in total. Quote Link to comment Share on other sites More sharing options...
cackshifter Posted December 12, 2018 Share Posted December 12, 2018 But I think the transfer box is usable, if you don't mind the 1.2 ratio rather than the 1.4. Quote Link to comment Share on other sites More sharing options...
Ex Member Posted December 12, 2018 Share Posted December 12, 2018 Yes. It is much more than 30mm!!! And, yes, pretty sure the TD5 input shaft is completely different. Then there is the shifter relocation issue. Quote Link to comment Share on other sites More sharing options...
gilloverland Posted December 12, 2018 Share Posted December 12, 2018 depending upon the year, the D2 transfer box may not have a diff lock. Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted December 13, 2018 Share Posted December 13, 2018 Yup, it is about 6" different. Quote Link to comment Share on other sites More sharing options...
Tim2809 Posted December 13, 2018 Share Posted December 13, 2018 (edited) input shaft different lengt, spigot bush dofferent diameter, splines different, bell housing different length. it wont be a direct fit and needs stripping and bits swapping to make it fit. search on here td5 r380 into 300tdi will give you info on what needs to be swapped Edited December 13, 2018 by Tim2809 Quote Link to comment Share on other sites More sharing options...
Tim2809 Posted December 13, 2018 Share Posted December 13, 2018 Quote Link to comment Share on other sites More sharing options...
roamingyak Posted December 17, 2018 Share Posted December 17, 2018 LR made for a while a 'short bell housing' or 'stumpy' R380 for the 200TDI - I have one fitted. Ashcroft sell them, but they are quite expensive from memory... Maybe try to find the casing and build it yourself? Quote Link to comment Share on other sites More sharing options...
western Posted December 17, 2018 Share Posted December 17, 2018 I have a Stumpy R380 behind my Defender spec 200Tdi, My first one was a genuine brand new LR unit, the current one is a Ashcroft unit my old broken R380 was taken in part exchange. the rarest part is the 11cm long clutch housing. Quote Link to comment Share on other sites More sharing options...
Maverik Posted December 18, 2018 Share Posted December 18, 2018 I've got same as Ralph, its done very well for the past 10 years, not overly happy with the ratio's in mine (a bit short), much prefering the latter given by a late model LT77's but pretty happy with it. Quote Link to comment Share on other sites More sharing options...
reb78 Posted December 18, 2018 Share Posted December 18, 2018 18 minutes ago, Maverik said: I've got same as Ralph, its done very well for the past 10 years, not overly happy with the ratio's in mine (a bit short), much prefering the latter given by a late model LT77's but pretty happy with it. I thought they were the same Mav? What ratios are you running?? Quote Link to comment Share on other sites More sharing options...
Maverik Posted December 18, 2018 Share Posted December 18, 2018 I knew this might come up, I'm not entirely sure, the box was built by AW transmissions, I looked into at 1 point and I seemed to remember it resembled the gearing from a TD5 era box. and it does indeed drive just like my farther in laws 2003 Td5 90, unfortunately I had little clue of gearbox ratios back when I got it built, so whatever was had a believe was thrown in. I need to dig through my notes and see if I can find the gearbox code again. I was looking at getting my transfer box built up with some of those new gear sets (1.3) Ashcroft are producing now. I recon that would put it right on the money. Quote Link to comment Share on other sites More sharing options...
western Posted December 18, 2018 Share Posted December 18, 2018 More info here https://www.ashcroft-transmissions.co.uk/manual-gearboxes/short-bellhousing-r380.html Quote Link to comment Share on other sites More sharing options...
reb78 Posted December 18, 2018 Share Posted December 18, 2018 (edited) 55 minutes ago, Maverik said: I knew this might come up, I'm not entirely sure, the box was built by AW transmissions, I looked into at 1 point and I seemed to remember it resembled the gearing from a TD5 era box. and it does indeed drive just like my farther in laws 2003 Td5 90, unfortunately I had little clue of gearbox ratios back when I got it built, so whatever was had a believe was thrown in. I need to dig through my notes and see if I can find the gearbox code again. I was looking at getting my transfer box built up with some of those new gear sets (1.3) Ashcroft are producing now. I recon that would put it right on the money. http://www.red90.ca/rovers/gears.html might help? Edited December 18, 2018 by reb78 Quote Link to comment Share on other sites More sharing options...
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