Hi Everyone,

I just picked up a 95 Disco 1 5spd with 200,000km (125k miles) and no service history (I know, but it was cheap!).

I have been going through the vehicle and servicing all the fluids. So far I've done axles, tcase, motor and changed out the old (I presume ATF) gearbox fluid for Redline MTL.

Prior to changing the fluid, I noticed that shifts were notchy and clunky from 1-2 and 2-3 to the point where I would wince when changing gears. Slowing down gear changes seems to help but by no means does this box feel "tight".

When I drained the fluid today, I saw about 1/4" to 1/2" of very fine metal shavings on the drain plug magnet. Uh oh I thought. I had a good dig around in the oil catch pan and didn't find any bits of teeth of synchros which I'm assuming is good news (??!?!). The fluid was definitely down about 100-200ml

Took it for another run after topping up to the correct level with new fluid and shifts are much improved but they're still clunky and notchy on the upshift in the lower gears (downshifts are fine). The box is a hell of a lot quieter now the gearbox and tcase have been serviced but I'm still not 100% confident in the condition of the mainbox. Again slowing changes down really helps to the point where I can eliminate clunks but this thing shouldn't drive like a 1960s Series II Rover should it??? I'm thinking sychros might be worn or on their way out...

I'm also getting a few driveline clunks but this could be propshafts/bushings which are next on my list to start poking around with. Also masking things is my extremely rattly cats which need to be cut out ASAP so I can get a better feel for where all the various noises are coming from.

Anyway, does anyone have any insight into my sloppy R380? Any advice on other things to check? Clutch fluid bleed/flush? linkages? bias plate? Or should I expect to be having to pull the box in the near future?

 

Sounds like your on point. They are not the smoothest transmission. Needs a build, but I would just ride it out.

 

Double clutching from 1st to 2nd gear really helps this box, as does pausing in neutral in the lower gears. I think I can live with it - a gearbox rebuild is out of my comfort zone for now...

 

Box is definitely smoother with the Redline and seems to get better with more miles on it. I guess it takes time for the active ingredients to properly lubricate all the friction surfaces and do their magic. It's still not "perfect" but it'll do.

 

I would also do another fluid change. If it is getting better with just fluid than I would change it one more time and then see what you have. If its the same damage is done. With a manual there are wearable parts, but not like an auto. If it seems to be better. Change one more time and then call it good until it really makes noise and then youll know. But there should be plenty of people around that can rebuild an old 5 speed.

 

Good suggestion, thanks - will give it a try at some point.