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Got myself a 95 disco

R

rustyknuckles

Shifting Up
Hello everyone I'm new to the forum and would like some advice from anyone who can help. I bought a 95 disco commercial today in Ireland which has been in Ireland since first registered. To my surprise it came with ten months of a DOE test remaining and with this being a yearly test and a very thorough test at that it assured me there was no rot at all. On looking under the mats there is just that, no rot at all, even the rear body cross member is solid.
It looks like I have a series 1 (2) (with the bigger lights and rear bumper light clusters) 2.5L 300tdi TD 14 with an R 380 box. My problem is with the box 'I think', she is noisy particularly when accelerating in fourth, she snicks going into all gears and generally gets noisier as the journey progresses. There is also tons of backlash and all uj's are fine with no appreciable backlash in the diffs. Has anyone changed an R380 box, is this the only problem associated with these noises or are there likely to be transfer box problems also? Where is the best place to source a recon box?
Any help will be most welcomed, I'll post some pics tomorrow, just busy finding out that the 5 gallons of water on board are coming in from the windscreen and the rear door seal, door appears to be twisted a little. No sunroofs and alpines are blanked which narrows the game a little thankfully.
 
Thanks Peter, looks like I'm in for some heavy work. How do I tell if the transfer box is good or not, don't want to replace the box and still have loads of backlash. If I disconnect the props will I be able to tell if it's ok?
David
 
Generally speaking, the transfer box is much more simple and rugged than the main box, however the output shaft splines wear, this was caused by lack of lubrication. This is visible as soon as the transfer box comes off the main box.

Later boxes have the input gear in the transfer box cross-drilled to allow oil to enter the gear/spline area for lubrication, this cured the problem.

You'll get backlash whatever happens, there's a lot of gear mesh points in everything.

Drain plugs are magnetic, look for debris when you drain the oil.

Peter
 
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