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Mean Green

Member Since: 15 Sep 2011
Location: South Ayrshire
Posts: 278

Transfer box swap.. what else do I need

I am going to swap the LT230 in my 200tdi 90 for one from a disco to get the 'better' gearing.

Just wondering if anyone else has done it - other than the 'box what else will I need? Gaskets, seals etc. I want to have everything to hand before I start.

20th Dec 2015 10:28am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

A tube of rtv sealant, transfer box oil and new nuts and bolts for the props. Might be worth putting new handbrake shoes in whilst you're there too? 2002 90 Td5 Station Wagon
1990 Vogue SE
Triumph Tiger Explorer 1200
Td5 90 Thread http://www.defender2.net/forum/topic50767.html
Tdi 110 Thread https://www.defender2.net/forum/topic69562.html
RRC Thread http://www.defender2.net/forum/topic54492.html
Instagram http://www.instagram.com/george_grafton

20th Dec 2015 10:37am

Retroanaconda

Member Since: 04 Jan 2012
Location: Scotland
Posts: 2557

Assuming the seals etc. in the new box are ok...

Mounting rubbers (if required)
Propshaft nuts
Might need to sort handbrake mount
I would get a new input seal in case you damage it putting the box on
Cross-drilled input gear if not already fitted (would be silly to put a box without one on)
Oil

Would be a good start.

20th Dec 2015 10:38am

steventheplumber

Member Since: 29 Apr 2014
Location: Lincolnshire
Posts: 767

1987 Defender 90 200 Tdi HT Keswick Green

When I had my one done they changed over the speedo drive. I believe they are different colours and can be a pain to remove. Also something to support it when removing/ installing the transfer box. I think it is a great improvement and is quiter does not rattle as much.

20th Dec 2015 3:19pm

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 7703

2011 Defender 110 Puma 2.4 USW Stornoway Grey

propshaft tool will speed the job along nicely Cheers

James
110 XS Utility
130 Puma Station wagon/camper (in the making)
90 Puma Hardtop

20th Dec 2015 9:01pm

I Like Old Skool

Member Since: 23 Feb 2015
Location: Manchester
Posts: 768

1994 Defender 110 300 Tdi ST Coniston Green

grafty99 wrote:
A tube of rtv sealant

What for?

20th Dec 2015 10:11pm

LRmud

Member Since: 22 Oct 2014
Location: IV12 Highland
Posts: 198

If you can knock up a support bracket (in steel or timber) it's a bonus.
I made one that I then strapped onto the Transfer Box and made the job pretty easy.

Click image to enlarge --------------------------------------------------------------------------------------------------
1989 Defender 90
Toyota Aygo & Honda FR-V

20th Dec 2015 11:31pm

sharkey964

Member Since: 05 Oct 2014
Location: On a muddy track
Posts: 570

2007 Defender 90 Puma 2.4 XS CSW Santorini Black

I cut some long (about 6") pieces of threaded bar,to make lining it up when sliding it on to the input shaft easier.
Its a heavy lump to hold in position on your own.
Marc

21st Dec 2015 7:13am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

I Like Old Skool wrote:
grafty99 wrote:
A tube of rtv sealant

What for?

Assuming you want the sump off to clean it out/inspect before fitting again assuming its not a new one... 2002 90 Td5 Station Wagon
1990 Vogue SE
Triumph Tiger Explorer 1200
Td5 90 Thread http://www.defender2.net/forum/topic50767.html
Tdi 110 Thread https://www.defender2.net/forum/topic69562.html
RRC Thread http://www.defender2.net/forum/topic54492.html
Instagram http://www.instagram.com/george_grafton

21st Dec 2015 10:03am

Timo

Member Since: 14 Jul 2011
Location: Peterborough Ontario
Posts: 171

1984 Defender 110 300 Tdi SW Alveston Red

LRmud wrote:
If you can knock up a support bracket (in steel or timber) it's a bonus.
I made one that I then strapped onto the Transfer Box and made the job pretty easy.

Click image to enlarge

That is brilliant! Series II in pieces
1984 Defender 110 (3.5l V8 now 300TDI)

5th Jan 2016 4:25am

Mean Green

Member Since: 15 Sep 2011
Location: South Ayrshire
Posts: 278

Retroanaconda wrote:
Assuming the seals etc. in the new box are ok...

Mounting rubbers (if required)
Propshaft nuts
Might need to sort handbrake mount
I would get a new input seal in case you damage it putting the box on
Cross-drilled input gear if not already fitted (would be silly to put a box without one on)
Oil

Would be a good start.

What do you need to do with the handbrake? Is it a different cable?

11th Jan 2016 11:43am

Retroanaconda

Member Since: 04 Jan 2012
Location: Scotland
Posts: 2557

Sometimes there's a different mount for the handbrake on a Disco box to the Defender, so it has to be changed over. If I recall correctly this may mean drilling/tapping the mounting holes into the transfer case (the bosses for this are already present).

Not sure if this applies to later Defender boxes which have the direct cable entry handbrake though.

Should be fairly easy to tell by just looking at the two boxes.

11th Jan 2016 12:34pm

Martin
Site Admin

Member Since: 02 Apr 2007
Location: Hook Norton
Posts: 6486

2015 Defender 90 Puma 2.2 XS CSW Montalcino Red

If you are using a Discovery 2 transfer box you will need to swap over the entire rear housing as there is no speedo drive hole.

1988 90 Td5 NAS soft top

2015 D90 XS SW

11th Jan 2016 1:39pm

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