R380 Transmission Replacement

JohnnyO · January 22, 2021, 09:45 PM

The Rover had catastrophic transmission failure last Saturday. :-\ I was driving West from Calgary on the Trans Canada and with my foot to the floor to make the hill approaching highway 22. The speedo had just dropped below 90 kph and I felt something give and the motor rev'd like crazy. I was able to roll down the other side of the hill right into the PetroCan - very lucky.

After a few choice words I discovered I still had 4th gear. I immediately drove it straight to my shop in the NE, Pro-Active Automotive. I heard from Audrey there today that the transmission was out of oil and there were some nasty looking bits on the magnetic plug.

So, now I'm looking for some words of wisdom on a replacement R380. I'm thinking my options are:

1.) Look into rebuilding the R380
2.) Find a (hopefully) known good used R380 ($3,000 + cost of used transmission)
3.) Order a rebuilt R380 from Ashcroft ($6,000 quoted)

There's 280K kms on the truck. The prices quoted include the recommendation of replacing the clutch at the same time. I have a stack of receipts from the original owner and the clutch was done at 256K kms in October 2013. No receipts for any work done to the transmission.

This is way over my head to think of doing myself so I'm fine hiring the professionals to have it done properly. I do though have the option of sourcing the parts myself.

headdamage · January 22, 2021, 10:53 PM

It should be closer to $2000 for a rebuild unit from ashcroft assuming you do the work yourself.

binch · January 23, 2021, 12:25 AM

Ran it out of oil....ouch!!!!! :o

Another option is to contact Dave Beaumont at Beaumonts 4x4 gearbox specialists at:

https://www.4x4gearboxes.co.uk/gearboxes

They are the Ashcrofts of the north of England (in Halifax, Yorkshire) and you can buy a fully rebuilt one through them.

Depending on the state of the casing you can buy a rebuild kit and have it rebuilt, but get someone who knows what they are doing. I expect you'll have to open it up and see what the real damage is to the casing, shafts, bearings, gears, synchro, etc.

Keep us post John

Red90 · January 23, 2021, 06:36 AM

Quote from: headdamage on January 22, 2021, 10:53 PM
It should be closer to $2000 for a rebuild unit from ashcroft assuming you do the work yourself.

I'm confused as well. I just looked. It comes out to $1887 to your door for the gearbox. Clutch parts are a few hundred at best. Then labour. You can add another $500 for the heavy duty upgrades.

JohnnyO · January 23, 2021, 09:03 AM

I'll double check the quoted prices.

This is to be mated to a 4.6L V8. In my search for a used R380, I'm finding there are differences: The R380 for a 200Tdi uses a stubby bell housing and shorter input shaft. While the one for a 300Tdi has different diameter input shaft. There's also mentioning differences in the 'linkage'.

I'm hoping someone can put some context around these differences. Ideally I'd want to find a direct replacement. If I find something close what are the additional efforts/costs or are these things show stoppers? Can these parts be salvaged from the old transmission?

Red90 · January 23, 2021, 10:27 AM

You need to get a V8 version. The input shaft is specific to the V8. You also need a Defender version to have the correct shifter location. These were almost only made for NAS trucks so used ones are rare.

I would expect $2000 for the rebuilt box from the UK. $300 for clutch parts. $1000 labour to install including machining the flywheel.

Consider the heavy duty bearing upgrade. It will be worth it for long life. I would also install a new slave cylinder and flex hose as it is easy to do at the same time.

binch · January 23, 2021, 10:32 AM

Quote from: Red90 on January 23, 2021, 10:27 AM
You need to get a V8 version. The input shaft is specific to the V8. You also need a Defender version to have the correct shifter location. These were almost only made for NAS trucks so used ones are rare.

I would expect $2000 for the rebuilt box from the UK. $300 for clutch parts. $1000 labour to install including machining the flywheel.

Consider the heavy duty bearing upgrade. It will be worth it for long life. I would also install a new slave cylinder and flex hose as it is easy to do at the same time.

Good call ;)

grizzlychicken · January 23, 2021, 09:34 PM

Does sound transmission if your 4th gear works. Sometimes the output shaft on the transmission to T/F case strips too which can cause loss of drive but likely transmission if your 4th is working.
Agree with the lads here. After rebuilding mine the time it took probably would have been better to get an exchange rebuilt one. Unless you like to tinker! As John said they are around £1000 but the shipping kills you and it's expensive to ship back for the core charge so not really worth it to send back.
Keep in mind if you rebuild yours that if the gear completely stripped that all that shrapnel gets caught in everything. So at least all new bearings plus gears and that's assuming the housing is still good. Sometimes with a bearing failure the bearing seat can be loose and rattle around and wreck your housing.

Thats what happened to my transfer case failure anyway. Tricky to pull apart too as there is a press collar on the main output shaft that is difficult to remove. You probably could get an inspection camera in there somewhere though if the transmission is out. I have one you can borrow if you need.

Think I documented my transmission rebuild early in my build log.
Britannica restorations has a good guide too which gives you an idea of the work involved:

https://youtu.be/tb_4xzwHDpw

The nice thing either way is you can upgrade your 5th gear to a higher ratio.
I would get a rebuilt one from Ashcroft as my vote.

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Red90 · January 24, 2021, 09:38 AM

The price I show above includes shipping and core fees. It is all in except import fees which should be 5%.

He will also already have the higher 5th gear ratio. They are the normal gear ratio on V8s.

binch · January 24, 2021, 09:53 AM

Did you account for the VAT for the core being returned to UK? I wouldn't have thought it would be possible but when I sent my injector pump back to Breedon & Gell for a rebuild I was charged VAT to bring it into the UK...even though it was clearly identified that it was there for repairs only and will be returned to me. That was an extra 19% on the part going in and 19% on the repair charge coming out.

Mind you....I declared the value of the part at $600 (the replacement value if it was lost in shipping) and I'm not sure that was the issue. But anyway I looked at it I got stung on that one!!!! >:(

Red90 · January 24, 2021, 10:55 AM

My price above is with not retuning a core. John will not have a useable core.

Like I said $2000 delivered to your door all in.

If you are someone with a useable core you can sell it locally. Shipping it to the UK does not make sense.

binch · January 24, 2021, 12:16 PM

Yup, I agree.

JohnnyO · January 30, 2021, 03:46 PM

Well I pulled the trigger on the Ashcroft. The estimate came close. I could have saved some by ordering it myself or taking the time to find a used one. This way it'll be done right and there be more to go on if something goes sideways. Plus I figure it's a good deed by shopping local. Wish me luck!

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