RRphil might be able to advise on this but if you can why not get hold of a cheap 2000-2005 X5 3.0d gearbox and get the core of it rebuilt and dropped into yours?

The x5 uses the GM 5l50e gearbox which is much stronger than the 4l40 unit and rated for more torque and vehicle weight(though still not really as high as the FF or x5 weighed.

http://www.aulro.com/afvb/l322-range-rover...specs.html FFRR MY06 facelift With TDV8 Alloys Zeros/ATR's
Mantec Sump Guard, Rigid Load liner, MY10 BT upgrade.

Also here appears to be another person who has gone for upgraded parts for their gearbox from a 5l50e...

http://www.rangerovers.net/forum/6-range-r...own-9.html FFRR MY06 facelift With TDV8 Alloys Zeros/ATR's
Mantec Sump Guard, Rigid Load liner, MY10 BT upgrade.

The ffrr's went to hospital for surgery today, hopefully I'll have a fully functioning GM cheese box early next week, I've opted for a new, not recon, torque converter, and hopefully that will cure all the probs. While they have it out they are going to strip it down to check the condition of the rest of the box.... every thing crossed  Yesterday I couldn't spell Engineer... Today I are one!
Inventor of the 'Guide-o-Matic automatic wheel alignment tool'
Former long term L322 owner, Up/Down graded to a Classic Tractor!

Is it off to France as I hear they do good cheeses.... 😉😉 FFRR MY06 facelift With TDV8 Alloys Zeros/ATR's
Mantec Sump Guard, Rigid Load liner, MY10 BT upgrade.

It's back

Had a new torque converter fitted, oil pump and the valves in the pump were done too.... and then they had to strip the gearbox to remove all the swarf that had come out of the failed new fleabay torque converter Top job by Sta of Alyesbury, they really do know their stuff, and insist on fitting Sonnex valves to all GM 5L40E gearboxes

Nice smooth gear changes and it doesn't fight you when it's stationary.... unlike the old torque converter... which got so hot it's turned blue I'm sending it back to matey in the morning and I'm half hoping that he doesn't change his tune that there is nothing wrong with his converter, cos I reckon that a trip to the County Court would reap a better return than a straight refund..... the 2.1K that I've shelled out in repairs are a direct result of the new torque converter failure, and then there's the fact this has been going on for over 2 months and that I have lost 4K in earnings.... reckon that the CC is a better option than a refund... but the fact that it's gone blue is a clear indication that something has gone drastically wrong in the converter... We shall see  Yesterday I couldn't spell Engineer... Today I are one!
Inventor of the 'Guide-o-Matic automatic wheel alignment tool'
Former long term L322 owner, Up/Down graded to a Classic Tractor!

Glad to hear you're back up and running

Not sure CC will award you consequential loss - and you'd need to throw more money into legal fees to find out....

Good luck with whatever you decide

Glad it's mostly sorted now fella!

Before its sent off make sure you've got a full report in writing about it that someone is willing to stand with in court and loss of photos of the failed unit as well  FFRR MY06 facelift With TDV8 Alloys Zeros/ATR's
Mantec Sump Guard, Rigid Load liner, MY10 BT upgrade.

CC is a waste of time mate, as Alistair says, they will only be liable up to the cost of the TC unless you can prove they were reckless etc.... really not worth the hassle...


Glad it's sorted now, you can use it to tow that ML down the dump.....  Pete
__________________________________________________
2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Parchment over Navy Interior. Sold
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand, Jet Interior. Sold
2002 L322 Vogue 4.4 V8 Epson Green, Ivory over Aspen Interior (Fatty Offroader) Sold
-Click for Project Fatty off roader-

Not bloody likely.... I'm getting around 37 to the gallon in the ML

And now that I've sorted the machine gun locks for under a tenner I like it even more..... I hate to say this, but the ride is actually better than the ffrr .... But that might be down to the fact that it's done 194K and the springs are shagged

I will know more this week when I hook it up to a bog for the first time.... as long as it doesn't object too much and it isn't dragging it's bum on the ground, all will be good  Yesterday I couldn't spell Engineer... Today I are one!
Inventor of the 'Guide-o-Matic automatic wheel alignment tool'
Former long term L322 owner, Up/Down graded to a Classic Tractor!

glad your sorted mate.

Did my first tow with the ML today .... I brought the wrong car..... 2 Years ago

It really put the ffrr to shame..... the only thing that it didn't like was sixth gear... but it was more than happy in fifth, which at 55 is around 2000 rpm reckon I can live with that..... There's a steep hill going up to my pals yard where I borrowed the bog from and the ffrr struggles to get to 40.... the ML hit 45 with ease and then I had to back off, but it was still wanting to go What a difference an extra peddle makes... if only they had made the ffrr in manual, I wouldn't have been in this mess.....

One thing I did notice was the ML isn't as stable as the ffrr, but when I fill the back up with tools maybe it will be a little more planted  Yesterday I couldn't spell Engineer... Today I are one!
Inventor of the 'Guide-o-Matic automatic wheel alignment tool'
Former long term L322 owner, Up/Down graded to a Classic Tractor!