Ed Poore Posted July 18, 2011 Share Posted July 18, 2011 Does anybody have any suggestions on how to remove the primary pinion cover and oil seal assembly on a suffix D gearbox for a 1983 Series III? I've been tracing down a nasty grinding in the gearbox (notably when idle) which is definitely originating from by the rear of the bell-housing. Given that the 88" has done very little and was sitting for almost a decade in a garage before I acquired it I suspect the main input bearing has gone. It certainly sounds like it. Now my problem is that so far all the gaskets have required the large version of Land Rover's Special Tool #1 and a sharp screwdriver to break any gaskets to separate various components. Due to the shape of the bell-housing I can't get this technique to work (although I will persist in trying) to break the gasket between the bell-housing and the pinion cover. Having said that - looking in the workshop manuals, the green bible and various other sources it does look like I need to remove the securing nut on the layshaft to remove the bell-housing, I assume this is correct? Many thanks Ed Quote Link to comment Share on other sites More sharing options...
Snagger Posted July 18, 2011 Share Posted July 18, 2011 The lay shaft does need to be unbolted after removing the cast assembly that covers the lay shaft and input pinion bearings. You should have four nuts and two bolts removed from the bell housing-gear box interface, with two studs remaining in place. If that has all been correctly undone, a hefty tap from a rubber mallet should break the gasket's grip. This is the problem with sealants, though - using heavy grease smeared on both sides of the gasket is so much better as it seals equally ell but allows much easier and cleaner disassembly. Quote Link to comment Share on other sites More sharing options...
Ed Poore Posted July 18, 2011 Author Share Posted July 18, 2011 Thanks. Managed to get it off in the end by driving a small screwdriver bit in one side and managed to get a claw hammer to grip a lip through the clutch housing. Almost winded myself when it eventually came off and whacked me in the stomach. Bearing is noisy (one in the bell housing) and there's a substantial amount of play but looks in reasonable condition bizarrely. Quote Link to comment Share on other sites More sharing options...
Snagger Posted July 19, 2011 Share Posted July 19, 2011 Thanks. Managed to get it off in the end by driving a small screwdriver bit in one side and managed to get a claw hammer to grip a lip through the clutch housing. Almost winded myself when it eventually came off and whacked me in the stomach. Bearing is noisy (one in the bell housing) and there's a substantial amount of play but looks in reasonable condition bizarrely. Ouch! The bearing shouldn't have any discernible play in itself, but the pinion shaft will be able to wobble in a good bearing - a tiny amount of movement at the bearing becomes a large movement at the end of the shaft. That's why the front end of the shaft is held in the spigot bush (check and replace that while the box is out - it costs pennies but makes a big difference to the box, especially in 4th gear). Quote Link to comment Share on other sites More sharing options...
Ed Poore Posted July 19, 2011 Author Share Posted July 19, 2011 Ouch! The bearing shouldn't have any discernible play in itself, but the pinion shaft will be able to wobble in a good bearing - a tiny amount of movement at the bearing becomes a large movement at the end of the shaft. That's why the front end of the shaft is held in the spigot bush (check and replace that while the box is out - it costs pennies but makes a big difference to the box, especially in 4th gear). Ironically it was fourth gear that was the quietest when it was on the road, third was substantially noisier than the others. I'm wondering whether there's something slightly amiss with the layshaft since if I've understood correctly it's a direct drive (like on almost all Series / Defender boxes) and therefore doesn't use the layshaft. There's a local company who specialise in rebuilding gearboxes and a friend of ours recommends them so may take the bits there and see what they think and depending on cost will either do things myself or just get them to. Quote Link to comment Share on other sites More sharing options...
ejparrott Posted July 21, 2011 Share Posted July 21, 2011 Where is local to you, whats your location? Mine is extremely noisey in third, and I'm suspecting layshaft. Quote Link to comment Share on other sites More sharing options...
Ed Poore Posted July 21, 2011 Author Share Posted July 21, 2011 West Wales - essentially border between Carmarthenshire and Pembrokeshire, not local to you I'm afraid... Been busy on other stuff (like retrieving the 110 this afternoon, got it slightly stuck on the way back from cutting some trees down in one of our forestries) but if the weather holds out I'm going to be spending as much time outside as possible doing work on the land and then if it begins to rain will have another look at the gearbox. Quote Link to comment Share on other sites More sharing options...
ejparrott Posted July 25, 2011 Share Posted July 25, 2011 West Wales - essentially border between Carmarthenshire and Pembrokeshire, not local to you I'm afraid... You're right...cross the border regular but not that far down! I've been tipped off about a gearbox rebuilder in Coventry who's Series gearboxes are about half the price of Ashcrofts....As much as I'd far rather have an Ashcroft box, I cant really stretch to a whole grand if it suddenly lets go! Weather forcast good for another week! Quote Link to comment Share on other sites More sharing options...
Snagger Posted July 27, 2011 Share Posted July 27, 2011 You're right...cross the border regular but not that far down! I've been tipped off about a gearbox rebuilder in Coventry who's Series gearboxes are about half the price of Ashcrofts....As much as I'd far rather have an Ashcroft box, I cant really stretch to a whole grand if it suddenly lets go! Weather forcast good for another week! My local LR specialist doesn't use Ashcroft anymore - it might be bec ause they are trying to increase their own margins on gear box replacements, but they said to me that it's because Ascroft's quality is no longer what it used to be, having dropped when Ian Ashcroft handed over to David, resulting in a much higher return rate of faulty units. I did see a lot of Britpart boxes last time I visited Ashcroft's workshop. Worryingly, Turner Engineering use Britpart too. Sadly, I think both are trading on the name they worked so hard to make. Quote Link to comment Share on other sites More sharing options...
RobotMan Posted July 28, 2011 Share Posted July 28, 2011 I'd recommended Beaumont's in Halifax. Straightforward, down to earth and years of experience. btw don't forget that Britpart supply three quality levels. carp, decent and OEM. All come in those same blue boxes. http://www.4x4gearboxes.co.uk/ Quote Link to comment Share on other sites More sharing options...
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