a 96 should have the cross drilled input gear already. My 95 did.
The whine could be the rear bearings in the r380. Does it do it in all gears?
Not from the factory, they weren't fitted until '97. My '96 Disco didn't have one..
And my '95 D-90 didn't..
TSB's issued in '96 were still spec'ing the installation of the 'oil feed disc'..
Here is the Text of the Spline Wear TSB issues by Land Rover:
"Gearbox Mainshaft Spline Wear
Issue 2
24/05/96
37/02/96/US
SUBJECT:
Gearbox Mainshaft Spline Wear
MODEL:
Discovery
Discovery
Defender 90
AFFECTED VEHICLES:
LPLJ 178205 Onwards
LJ 506525 Onwards
LD 976480 Onwards
DETAIL
Some customers may complain of clonks and backlash in the transmission system. This may be due to gearbox/mainshaft spline wear. The clonk/backlash will be most apparent in stop/go traffic under overrun conditions or when maneuvering the vehicle during parking, etc. From transfer box numbers 28D460996 F (Discovery) and 22D 461124 F (Defender) all factory built LT230 transfer boxes have a revised design of input gear, featuring lengthened splines and cross drilled oil feed holes. This modification eliminates the
requirement for an oil feed disc (bulletin H415) and eliminates input gear/mainshaft spline fretting/wear. Coincident with this change, the transfer box identification number has been changed to Suffix "F".
Information only:
The new parts supercede all old parts and should be used in ALL LT230 applications during repairs.
NOTE: Do not use in conjunction with an oil feed disc, Bulletin "H415 Mainshaft Spline Wear Prevention." If a complaint of transmission clonk/backlash is made, it is likely mainshaft spline wear has occurred. The
transfer box mainshaft input gear and gearbox mainshaft must be replaced together as a pair.
ACTION REQUIRED
If a customer complains of transmission backlash/clonk refer to the
procedure below.
PARTS INFORMATION
Mainshaft/Input Gear replacement part numbers
Manual R380
FTC5087 replaces FTC4188, ratio 1:1.214,28 teeth
(Defender and Discovery)
FTC3703 - Gearbox Mainshaft (Defender and Discovery)
ZF Automatic
FTC5087 replaces FTC4188, ratio 1:1.214, 28 teeth
(Defender and Discovery)
FTC5090 replaces FTC3981 - Coupling Shaft (Defender and Discovery)
PROCEDURE
Follow procedure outlined in Workshop Manual Section 37 "Manual Gearbox", Section 41 "Transfer Box", and Section 44 "Auto Gearbox."
For ZF Automatics: When coupled to a ZF Automatic gearbox a new coupling shaft is required with extended splines. This is a factory fix for all Discovery Automatics and LT230 transfer boxes.
NOTE: If the clonk/backlash is thought to be coming from the transfer box, remove the power take off cover and bearing housing from the rear of the transfer box to inspect the input gear. Visually inspect the transfer box input gear and the gearbox output shaft if visible wear is evident, the gearbox output shaft and the ransfer box input gear will need to be replaced as a pair.
WARRANTY:
Normal warranty policy and procedures apply.
COMP.CODE:
3L9J
SRO:
37.20.88/26 - Input gear and mainshaft (manual) renew 10.50 hr.
44.20.88/26 - Input gear and coupling shaft (automatic) 7.00 hr."
Here is the Oil Thrower 'fix' TSB as well, issued before they started using the crossdrilled input gear:
"You have the oil thrower fix if there is a yellow X painted on the back of the T-case. None of the fixes can be done with an LT77s. This is the PREVIOUS fix. Mainshaft Spline Wear Prevention
29/03/96
H415
SUBJECT:
Mainshaft Spline Wear Prevention
MODEL:
Discovery - with R380 Manual Gearboxes
Defender 90
AFFECTED VEHICLES:LJ 081991 to 172377
LJ 500000 to 504330
LD 939976 to 972378
DETAIL
To prevent occurrence of mainshaft spline wear, an oil feed disc has been introduced into the LT230 transfer gearbox which can be retro-fitted to earlier vehicles providing a customer complaint of transmission backlash/clunk is not evident This disc is a preventative measure only and will not cure existing spline wear induced "clunk" without other component changes. All transfer boxes from the above VIN numbers LJ72378, LJ 504330 and LD 972378 that are fitted with a feed disc at the factory are identified with a yellow "X" painted on the power take off cover so external confirmation of repair is visible, dealers should also apply this paint identification to identify completion of repair and to prevent this work being carried out again.
NOTE: Vehicles fitted with a LT77S manual gearbox CANNOT utilize this fix. Transfer boxes from suffix "F" will be fitted with a production solution which entails additional oilways in the transfer box input gear (detailed in Bulletin 37/02/96/US). Vehicles fitted with suffix "F" gearboxes cannot be fitted with the oil feed disc.
ACTION REQUIRED
At the earliest opportunity fit the parts listed below to all R380 vehicles, providing no customer complaint of backlash/driveline clunk is evident.
PARTS INFORMATION
FTC4993 - Oil feed disc (Qty. 1)
FTC4994 - "0" ring (Qty. 1)
STC611K - Hylosil sealant (Qty. 1)
NOTE: This fix cannot be fitted to LT77 or LT77S manual gearboxes.
PROCEDURE
See Workshop Manual for removal of the P.T.O. cover and bearing plate.
1. If during fitting of the oil feed disc, advanced spline wear is noted, both the gearbox mainshaft and the transfer box input gear should be replaced (if the replacement transfer gear has oil holes into the spline, an
oil feed disc will not be required, see Bulletin 37/02/96/US).
- Assemble "0" ring onto disc and locate disc into bearing housing ensuring cut outs are aligned and disc ID "TOP" is at the top of the disc.
- Rebuild referring to Workshop Manual, cleaning off all traces of old sealant.
- Paint a yellow "X" on the power take off cover.
Note: Do not rebuild with grease - if spline lubrication is required, use only transfer box oil.
NOTE: For guidance on repairs to resolve customer complaints of transmission backlash refer to Technical Bulletin 37/02/96/US.
WARRANTY:
Normal warranty policy and procedures apply
COMP.CODE:
H415
SRO:
H415 - Fit oil feed disc 0.90 hr.
NOTE: If any additional mainshaft wear is noted replace parts and claim
through normal procedures."
