1of40
Well-known member
Wow, this is disappointing to hear. I’m about to swap in a HD380 stumpy behind my 200. What do we mean by clunky?
LT230 Rebuild or Replace
- Thread starter Classic4X4
- Start date
donb
Well-known member
This
"Good" to hear about the noisy clutch/mainshaft chatter in neutral - mine is pretty noisy and I thought it was the throwout bearing/fork but was scratching my head as I "bench" tested that stuff the 2nd time I had it out and it worked well.
Classic4X4
Well-known member
Bummer to hear. I’ve actually yet to get a response from either of them. So hoping beginning of this week.
A good bit of news - had a nice break in the weather here and was able to do some diagnostics. Looks like the fuel leak isn’t the pump after all (thank the Lord) but rather the spill lines.
A good bit of news - had a nice break in the weather here and was able to do some diagnostics. Looks like the fuel leak isn’t the pump after all (thank the Lord) but rather the spill lines.
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Napalm00
Technical Excellence Contributor
You can replace them with Viton or urathane fuel line. I also use the double sided Cummins style copper gaskets. They are better than the Rover ones.
I like the urathane fuel line as it's see through. Seen here without the double sided coppers, they came later
I like the urathane fuel line as it's see through. Seen here without the double sided coppers, they came later
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Classic4X4
Well-known member
Thank you! I read a few of your posts on this topic in older threads - super helpful - I like this idea - looking at the OEM assembly (ERR3652) $90 - I’m noticing a tube coming out of the banjo bolt connecting to the injection pump that I don’t have on mine - strange thing is I can’t seem to find a similar setup anywhere online without that tube.
Seems like the best route is the Cummins washers and clear tubing!
Classic4X4
Well-known member
You’re right! - there it is
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Classic4X4
Well-known member
Will do! Replacement spill rail lines ordered and on the way.
I think I'll be placing the order with Winchester Gears today or tomorrow - awaiting shipping quote
LT230 "US Spec" w/ ATB and triple sleeved casing
R380 "Stumpy" - Any reason not to do the Heavy Duty build? is the driveability/shift quality compromised?
Also, anyone think my 200TDI w/300 Head/Turbo can handle the taller 5th gear option? would be with 1.4 TCase and 267/75 tires.
Should I have them send the two mated or separately? Planning on removing floors/seatbox and installing w/ engine lift.
Thanks gents!
Napalm00
Technical Excellence Contributor
heve them sent separately not mated will be cheaper due to the smaller pallet. You will also need the r380 style lt230 shift linkage. When you get them rebuild the shifters for the lt230 and replace the missing plastic inserts before installing. then with the units connecte dup use the shifter to adjust the linkages so the lt230 shifts and locks easily. mark where they are then remove the shifter remotes so you can install them. once the drivetrain is in the truck now you can just slide on the shifter linages and not fiddle with goign under and above the truck to get them lined up. will be bolt on. no need to remove the seatbox, just the floors and tunnel.
buy a set of new glencoyne mounts
get the HD, it shouldnt impact drivability .
I have the taller 5th in my truck with a 1.4 and 35.5in diameter tires. im also running a TDI making at least 2x the power of a stock unit. that being said you could go either way. if you live in a flat area like northern texas and are on the highway alot, go for it. If its hilly where you are or have inclines the taller 5th wont help you much as you will be downshifting to 4th often with the slightest incline since your truck is in stock tune.
I like the taller 5th but even with my truck and stock diff gears on 35s its really not needed, id be nearly as efficient with the lower gearing as it would keep my truck in the useable tq range longer and on boost. Still no regrets
buy a set of new glencoyne mounts
get the HD, it shouldnt impact drivability .
I have the taller 5th in my truck with a 1.4 and 35.5in diameter tires. im also running a TDI making at least 2x the power of a stock unit. that being said you could go either way. if you live in a flat area like northern texas and are on the highway alot, go for it. If its hilly where you are or have inclines the taller 5th wont help you much as you will be downshifting to 4th often with the slightest incline since your truck is in stock tune.
I like the taller 5th but even with my truck and stock diff gears on 35s its really not needed, id be nearly as efficient with the lower gearing as it would keep my truck in the useable tq range longer and on boost. Still no regrets
Classic4X4
Well-known member
Perfect - appreciate the incredibly helpful advice! Will have them sent separately. Currently awaiting a shipping quote.
I think I'll do the taller 5th gear - I took the Defender to MV over the summer and missed my ferry (thankfully they let us on the next) - I think a taller 5th will help with the tardiness. I have a 300TDI head/turbo setup so I (think) the power will be adequate.
Great story - Morning after arrival we drove into town to pick up buddies from the ferry. I noticed a nice black puddle under the truck when we got in.
Did a quick fluid check and decided to make the trek (very carefully) back to the house - I followed a black drip trail of oil on the entire route - pulled into the driveway and on comes the oil light (it works!)
Found oil dripping from the filter so took a buddy's car all the way across the island to Napa and bought a replacement
Installed - still leaking. Found it was just the oil line fitting above the filter housing -Tightened and fixed! - Just felt bad about the spillage. It's amazing what a few hour road trip will shake loose or break compared to driving around town for years.
In prep for the overhaul I've got a new fuel tank, drive belts and timing belt on the way. Currently assembling a separate cart for the trans/tcase including R380 Linkage and new mounts
Is there any reason not to install a heavy duty clutch?
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Happens a lot. Great looking truck. The ATB will help. I saw that you posted the tire size. I was going to suggest maybe going taller on the tires. My 110 Tithonus with the LT77 and LT230(1.61) I "cruise" at 65 MPH with the 235/85/16 BFs, although I have a different engine.
I will eventually upgrade to a LT230 with the 1.4, or just open mine up and rebuild and do the gear change.
Keep us posted on how it goes.
E
Classic4X4
Well-known member
Will do! I have the 1.4 with 265/75 and I think any larger would make 1st a pain. I did the 265’s in hopes of increasing top speed (barely helped lol)
Spill lines are coming Friday, but in the mean time I’ve fitted a section of clear aquarium air pump line - fits fantastic and the leak is stopped but I noticed no fuel in the line while the engine is running. Is this normal?
Napalm00
Technical Excellence Contributor
yes normal. if you put on vinyl aquarium line, its not going to last long. maybe a few weeks
normal to not see fuel there you will after you shut it down after a long drive
Classic4X4
Well-known member
I did find out it is a 1.4 box rather than the 1.6 as I had thought.
After speakig with Winchester they recommend not doing the taller 5th intended for the V8
From what I've read, the standard R380 5th is .77 while the Lt77 is .83 - Can I expect a top speed improvement or just marginal?
Aquarium line just installed so I could idle in the driveway to tension drive belts! Coming off tomorrow
Napalm00
Technical Excellence Contributor
no, no top speed improvement . none. zero . it will actually be slower to accelerate in 5th to the same top speed as before. on up inclines you will actually have a lower top speed. you arent making anymore power , just gearing it taller and making it more efficient
the 300 turbo you have on there will make maybe 1hp more than the stock unit. its all about fueling and boost. if you want to go faster:
advance timing
increase boost
adjust fueling
get boost and EGT gauge
the 300 turbo you have on there will make maybe 1hp more than the stock unit. its all about fueling and boost. if you want to go faster:
advance timing
increase boost
adjust fueling
get boost and EGT gauge
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Classic4X4
Well-known member
Got it - beginning to accept these things just aren't meant to move so quickly.
I can get to 55-60 on the highway, the damn thing just sounds like its on the verge of explosion past 2K rpm and the EGT climbs
I've installed an Alisport high-cap intercooler and VDO EGT and Boost gauges. To get to 55-60 I'm just over 2K rpm and 10+PSI boost.
I never let the EGT exceed 650f (should I?) - if boost is over 10psi the EGT needle climbs, if its under 10, the needle drops
It's never felt to me like I didn't have enough power, but always felt like if I had a 6th gear to shift into I'd be smooth sailing.
I remember reading Adamsanta's 200tdi tuning threads so I'll have to crack into those again
Napalm is completely correct, what you are moving is where the power is felt and what RPM your cruising is at. In my case, since I have a OM617 swap, the happy medium is much higher than the 200tdi.
Driving these motors without a boost gauge and EGT is asking for trouble honestly.
Driving these motors without a boost gauge and EGT is asking for trouble honestly.