The two main types of manual gearboxes that we supply are the LT 77 and the R 380. We also supply the LT 85 "Santana" gearbox.

How we rebuild them

When we rebuild a box, the unit is stripped down, washed in both Safety Kleen and hot wash tanks then the casings are shot blasted with glass bead, then painted. Once "Prepped" the stripped unit is sent to the build area in a plastic tub.

The boxes have a fixed set of new parts including bearings, baulk rings, gaskets and seals, approx 95% have a new mainshaft due to the spline wear they suffer from. Once the parts are picked the first step in the build process is to lay the parts out on the bench for inspection, the gears and shafts are closely inspected paying particular attention to the condition of the dog teeth and the wear pattern on the gear teeth. If they pass inspection they are used again, if not they go in the scrap, we cannot pretend we change every part or we would not be in this business very long but to give you an idea we change approx 40% of pinions, 50% of layshafts and about 60% of reverse and 5th gears.

Once built, the unit is stamped with a number and a spec sheet filled out giving us info on the unit specification, who built it, when it was built and exactly what parts were fitted.

Click here to see a video of an R 380 being built.

How to order

Should you wish to place an order for a unit you will need to first identify the unit required using the following guidelines then either phone, fax or email us (preferably fax) with your name, phone number, delivery address, what it is that you would like to order and payment details. Once the order is received we will contact you to give a delivery date.

When we send a unit out, we also charge a core charge which is refunded upon receipt of the old unit assuming it is the same type as supplied and must be complete and not stripped with an intact casing, these core charges vary depending on the type supplied as detailed in the relevant section.

What they arrive with

The manual boxes can be catagorised as "Long Stick" as fitted to the Defender and "Short Stick" as fitted to the Disco.

If your serial number starts with any of the following then you have a longstick : 50A, 51A, 52A, 56A, 60A, 61A, 66A, 68A, If your serial number starts with any of the following then you have a shortstick : 53A, 54A, 55A, 57A, 59A, 63A, 73A,

The longstick boxes come with the top casting that the gearlever and turret bolt to but you will need to remove the following from the old unit : the bellhousing and dowels, transfer case dowels, gearlever and turret and diff lock pivot bolt if fitted.Click here to see a video of what they come with.

The shortstick boxes come with remote top assembly with reverse switch fitted but you will need to swap over the bellhousing & dowels, transfer case dowels, extension gearstick and diff lock pivot bolt.Click here to see a video of what they come with.

The only exception to the above is the 64A and 65A, these come less bellhousing and less remote shifter.Click here to see a video of what they come with.

Identifying your Unit

There are three types of 5 speed mainbox, LT77, R380 and LT85 (Santana). The following questions will help identify which type of box you have.

1) Is reverse underneath 5th gear?

If yes, you have an R380 . Please go to point (a) to identify which type.

If no go to question 2.

2) Is reverse gear next to 1st gear?

You either have an LT77 or LT85. Question 3 will identify which one.

3) Is the maincasting black or aluminium?

If black you have an LT77, please go to point (a) to identify which type.

If aluminium, you have a LT85, Santana box. Please go to point (b) to identify which type.

(a) The gearbox number will be stamped or dot punched on the oval machined flat directly below the filler level plug, on the right hand side of the gearbox main casing. The relevant numbers we require are the first two and the last letter, i.e. the number may be 56A1234567G, we would call this a 56G. Click here to see a video of where to find this number. In some cases it may not be possible to read this number in which case we will need precise details about the type of vehicle you have, engine fitted and year to help us identify it.

(b) The sides of the aluminium housing will either be smooth, which will be a 20C, Solid Case, or cross hatched, which will be a 22C, Split Case

For information on Freelander manual gearboxes please refer to the Freelander section of our website