First time post after 2 years of ownership.

Sadly trouble free motoring has left the building and I'm replacing the inlet manifolds tomorrow having limped back from Cornwall to Kent in "restricted performance mode" this Thursday.

But the crux of this post is all about the transmission....

For the last 10,000 miles I've been chasing transmission issues - a weird almost "rattle" when accelerating hard and what was a gently "thunk" when changing from 3rd to 2nd (especially when no load on the transmission)

Over my two year ownership I've had the transmission flushed by an indy, and personally changed the front diff (it did need doing and it removed a lot of whine I could hear) and front driveshafts and wheel bearings.

But now this "thunk" is turning into a "bang" and I cannot ignore it any further!

Frankly I think its time to replace gearbox and transfer box from a scrap vehicle and see if I can get rid of this problem once and for all.

Does anyone know precisely what donor vehicles I can use - will units from a disco 4 /5 fit for example?

Also my biggest concern is the electronic side of the job. I do have an iid tool. Will I need to programme the box to the vehicle - I doubt its going to just swap straight over?!

Does anyone have any experience of this please?

Are you sure that your restricted performance isn't caused by leaking donut hoses? Can you see oily areas on the manifolds that hasn't come from 1 or more of the 4 hoses?
Does your engine have the special harness that stops oil migration from the oil sensor inside the sump to the primary turbo?

How is your rear driveline? The centre bearing can flop about causing thumping and the uni behind the TC might be chopped-out, athough I would expect a vibration for either depending on speed.

I would be visiting to a ZF gearbox specialist to diagnose the thumping if the rear driveline is OK.

Manifold is a done deal - I can see the crack on the RH (I'm doing both at the same time)

Rear driveline including the centre bearing is ok.

I should have mentioned its covered 105,000 miles (including a fair amount of towing and off-tarmac driving this last couple of years)

I could take it to a zf specialist.... but I reckon there is only one verdict and the most cost effective solution is to replace with a box from a scrapped vehicle.

Just wondering if anyone has done it themselves before and what units might fit. If a Disco 5 box is interchangeable then it would be easier to find one with lower miles on it.....

You need another box with the exact same part number, someone on here tried with one with a different last digit IIRC and although it was the same physical box it was not suitable...

It's a can of worms... good luck, don't forget you want the TC and the oil cooler and lines for the same box as well....

Can't see you will have any coding issues, you may have to do a bit but the IID should manage it...  Pete
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Would it be worth going to a specialist that you trust to just get their diagnosis on the subject / fault, then go from there, just in case they found something that could be rectified ? and save you time and money.

I am sure there are members on here that could recommend a trusted specialist.

I have read good reviews from this place?

https://www.dartfordtransmissions.co.uk overfinch modified

Before spending thousands on a new box it may be varnish build up in the galleries and solenoids. You could try adding 1/2l of a strong solvent like SeaFoam TT16 (trans tune). I do have some on sale on eBay as do other sellers and the feedback I have had for this product has been good.

If you do try it look for our DL retail listing and I'll do you a 10% forum contributor refund. Just identify yourself through a message as off the forum.

Last edited by baz000000 on 14th Aug 2023 12:29pm. Edited 1 time in total

Depending on where you are in Kent, might be worth getting a second opinion on the driveline from QP Online at Maidstone.

Thanks for replies.

QP online is closed till September for holidays.

I shall try dartford Transmissions.