Had a similar issue with similar noise. End float was all within spec, but when fitting reverse / 5th gear would get a clunk. Had fitted new main shaft. What I found was the shims on the main shaft to reduce the end float was causing the reverse gear to contact the intermediate plate. To fix I had to reduce the shims on the main shaft and machine a shim on the input shaft bearing to achieve the correct end float. Noise gone. Thanks for the content and information.
I had a noise with mine, I thought it was the clutch, I was getting rattling in neutral. Turns out it’s common for the teeth to chatter when cold and in neutral. The noise goes once it’s up to temperature
Hi Mike. Nothing to do with this video. But if you could remember probably not a will ago..I asked a question about a disco 1 changing a automatic box for a manual. And changing a electronic diesel pump for a manual pump .we'll I went with my intuition and learning of you channel I have done it.i bought a ashcroft box .a pump and had it checked off diesel bob of England and its a OK.thats why we look and learn off channels like yours.keep up the good work Mike what will we do when electric takes over.fn knows.many thanks my friend.
23:13 To change from td5 to tdi its easy you just need the to buy the inputshaft(TUD102580), but from a tdi to td5 it need machining, because of the OD and height of bearing in the front plate of housing(there are no shaft for td5 with "tdi bearing" ). i thing the v8 have less or more teeth, and the layshaft is different too. I have a td5 r380 on my 300tdi, and i just have to change the input shaft and bellhousing. To change the input shaft it's tricky, i made the lay shaft lose, to make space to the input shaft pass on the 4th sincro ring(without taking the everything apart)
Hey Mike, the next time you’re looking for sockets try Tekton. You can get a 38 mm deep impact socket for like $14 US. And they have a great warranty policy just take a picture of the broken tool. I’ll upload it and they’ll send you a new one in a couple days.
There is nothing worse than someone who is playing the gearbox when they know absolutely nothing about the chatter that commonly occurs in the gears. Japanese fixed it with a little tin plate with a spring on it so the girls were constantly intention but not so for the British manufacturers
well i am not shure if it helps, but maybe it would be nice to know how much miles the gearbox ran and if someone overhauled the gearbox and what changes exactly have been made and what not. this would be my starting point. from my novice point of view this ratling noise comes from excesive play of the shaft. but where - the shaft itself, maybe some bearings are out of specs. which is not something new. this looks more and more like a crime scene - CSI britannic restoration- lets see how it continues
What are the marks in the gear teeth at 18.57? Maybe that's what was partly on the drain plug magnet? No idea what I'm looking at in terms of noise so no help, but I'm sure you'll have it up and running as it's supposed to be in no time.
JP measured up the rear housing and the housing for the bearing is 0.001 oversize which is why the bearing fell out - could be the source of the problem
