Rovers North

The MT82 6 speed gearbox fitted to the 2.2 and 2.4 TDCi is prone to the spline on the rear output shaft wearing which causes a total loss of drive, this spline 'frets' as it is dry in the same way the earlier LT77 and R380 mainshaft splines wear in the transfer case input gear, same thing, different spline. The MT82 mainshaft comes out of the gearbox and a female/female coupling shaft (LR030054) is fitted to this with a large bolt. A male/male coupling shaft (TUD500020) then fits into the LR030054 and the other end goes into the transfer case input gear. The spline that wears is the one at the rear of LR030054 and the front of TUD500020. We have devised a method to make this splined interface wet with oil which stops the wear. We take a new LR030054 and spark erode two small slits in the front face where it fits to a bearing, also remove two teeth from the front spline at 180 degrees to eachother, then spark erode another two small slits on the rear face under the clamping bolt, this now allows oil to 'leak' out of the mainbox to this spline. We also turn a thread on the outside diameter and also make two O ring grooves. The TUD500020 has a ground diameter that the transfer case input seals runs on, we take a new part and regrind it to run this diameter further up towards the gearbox. We then make a new part which slides over the TUD500020, this has a seal fitted to the rear which seals on the new ground diameter and has both a diameter to seal on the O rings and a thread to fit it to the LR030054. A spanner is supplied to fit this part.