Defender transfer box removal. From underneath using only a jack.
Check two inner (main/transfer) bolts are oil. Remove the seatbox & tunnel, stand astride and lower / lift the lump into position (gearbox & transfer-box separately). Prop off. Front and then rear view:-First drain the transfer case - 17mm socket or spanner to remove it. 2) Take two pieces of of 16 gauge steel and drill holes in the steel that line up with the four central bolts in the bottom cover of the transfer case. Here is a summary how I went about to remove it (I might have missed some steps in my list). Defender 300Tdi (1994-2006) Defender Td5 (1998-2001) Defender Td5 (2002-2006) Defender 2. 26. For a 110 you might well be best off with a 1. For the heavy transfer box, made an adapter that bolts to the bottom plate of the transfer box and bolts to a trolley jack. remove the PTO cover off of the Mar 21, 2017 · So I'm curious to get some more thoughts on this. 003. 2. Lead in before we repair the transfer box. Hope that helps. AJ126 AJ133 AJ200 204DTD AJ200D All Models Defender Defender - 1987 - 2007 Defender - 2007 - 2016 Defender - 2020 onwards Defender - NAS Defender 110 Defender 130 Defender 90 Discovery 1 Discovery 2 Discovery 3 Discovery 4 Discovery 5 Discovery Sport Freelander Freelander 1 Freelander 2 Lightweight Lightweight & Military Military Ninety One Ten Mar 1, 2018 · Step 12: Fresh EP90 gear oil is pumped into the axles and transfer box using this transmission oil filler. #landrover#defender#LT230 This manual contains procedures for overhaul of the LT230Q transfer box. If you are goin Transfer Box Fluid Type: Hypoid gear oil, viscosity SAE 80EP or SAE 90EP to API GL4 (Non-TD5 models) Castrol Syntrax 75W/90 (TD5 models) Front And Rear Axle Fluid: Hypoid gear oil, viscosity SAE 80EP or SAE 90EP to API GL: Manual Transmission Fluid Capacity: 2. Have access to the RAVE, but the images and instructions are pretty basic. 2 transfer box and it will be fine pretty much exactly the same as the Disco apart from the aerodynamic issues over 50MPH. Used a load-leveler at the front and a nylon strap at the rear. 2 box will be harder if you do alot of towing or live in a hilly area\, otherwise go for it a great mod and Dave will look after you. This explains why it isn't fully drained yet. Prefixes 28D and 34D - Discovery Serial No. 7:1, does anybody know what LT230 ratio would be best to make this all work. 32) and super low (6. Prefix 38D and 40D – Defender The transfer box is a vital component in providing your Defender with the rugged 4 wheel drive experience it is known for. Pulse Mar 3, 2012 · Could somebody please help me, what would you recommend as the best oils/fluids etc to use in my 1993 Defender 90? I want to drain the oils out of the gearbox, transfer box and both axles/diffs and replace with nice brand new stuff - as I have no idea when it was last done. have to fix hand brake at same time so will probably do this way! 3 remove front grill and remover engine, gearbox and t box as one! https://www. me/britrest2018Your support is appreciated!If you have a Defender/Tdi problem and do not know how to fix i Nov 20, 2019 · Transfer box removal. Page 169 TRANSFER GEARBOX Refit 42. 28D sx C to 308626E = 1. It's quite normal to have a fine paste of steel on the magnet, but this one was surprisingly clean. This transfer box is fitted to the following models: Serial No. From underneath using only a jack. 4 litres and the oil spec 75/90 full synthetic gear oil - is that correct? Jun 9, 2019 · In this video I remove the transfer box, replace the input shaft seal and then refit the Transfer box, Enjoy. the above was then superceeded by the 36D in the disco 1's which were 1. Anyway, after I had mopped up the mess etc, I found a bolt which so far has eluded the focus of my eyeball (on the left hand side of the transfer case, almost at the very top. the only thing is it revs higher at 60 /70 mph. Feb 11, 2011 · 22. Watching various videos it doesn’t look to hard to change the O rings on the shaft. https://www. Prefix 36D and 37D – Discovery; Serial No. The oil catch plate has done its job – the drum is clean Land Rover Defender Gearbox and Transfer Box Whether your Defender uses a LT77, R380, Puma or Automatic gearbox we have the necessary parts to effect a comprehensive repair. Feb 19, 2012 · A disco box in a defender will bring your gearstick up as in the pic below. Feb 22, 2020 · Hi all, can you remove a 200tdi engine with the gearbox and transfer box attached? I. Input shaft spline LT230T TRANSFER BOX OVERHAUL MANUAL Thistransferboxisfittedtothefollowingmodels: Serial No. I used a Discovery transfer box on mine and swapped the rear output housing from the 1. I turned on the lights, the fan - I tried every switch. Les. Range Rover Classic - NAS with Borg-Warner transfer box except 1990 model year. I dropped my gearbox and transfer box out together with no issues on my own so you will be fine if there's a few of you Steve 2015 2. I also need to change oils in both g/box and t/case anyway, so it's an opportune time. Since the Defender which this motor and gearbox came out of had differential ratios of 3. May 25, 2007 · The transfer case, and its position under the vehicle. There is a plastic cover on the shaft. Thanks for the write-up Marco, it's just great and timely for me! Sep 25, 2011 · to replace the bolts, you have to remove the flange from the axle or transfer box depending on which bolts are wrecked, to do your just cut the bolt with a hacksaw to get the prop off. Recently I tried to shove the transfer case lever into LO range, probably for the first time in two years. See Repair, Transfer. Box off as Steve says. But l cannot find any videos on how to remove the transfer box. remove xmember, and drop gearbox and t box together-makes mating gearbox and tbox easier. Sep 17, 2019 · I have removed / fitted gearboxes & transfer boxes several ways over the years and almost always single handed. Now, I thought I had a properly sealed set of gearboxes finally, but noticed a drip on the drive (that's what started me off on this thread) coming off of the front bottom bolt of the transfer box plate. Remove 4 nuts and disconnect propeller shaft. The box is down, I borrowed a gearbox "jack" and made my own "special tool" a plate with 2 holes (8mm) and one 10mm hole. 4 Tdci (2007 - 2011) Defender 2. 2007 Defender Puma Tonga Green Mar 30, 2019 · *Did our video help you? If so, consider buying us a beer: https://bit. This manual contains procedures for overhaul of the LT230R transfer box. but that aint cheap if ya visit ashcroft site , around 190 quid per diff Sorry thought you were putting it in a disco May 23, 2013 · However, if you do need to remove the drive gear and the housing is stuck, the only way ive found to do it without damaging the housing is to remove the complete rear output housing from the transfer box so that you can get to the back of the speedo drive to tap it out with a punch. 6. Buying new Land Rover parts; Should I buy 24. 27. Lubricate oil seal in joint face of transfer box. think the best option is to change diff ratios . If you "upgraded" a Discovery to use the 1. The transfer case halves must not be allowed to separate. I can recommend doing a bit of research to make sure that you: Want to do it yourself; Can do it yourself; My method involved using an engine crane through the drivers door to suspend the gearbox and transfer box which I then removed, moved back and lowered individually. Mar 7, 2013 · Yes. Is it the same or do you have to remove loads of other stuff (air condition fascia or evaporator) just to get to the bolts? Whilst Damon has the transfer case out of his discovery 1 he replaces a leaky o-ring that can cause quite a bad leak over time and is a cheap and easy fix. Mar 29, 2023 · I put regular gear oil in the transfer case (green) and redline MTL in the LT77 gearbox (red), and while the oil that is dripping appears green the transfer case is actually still full and it's the gearbox that is steadily losing oil. gearbox . 222 gearing, and to give me some flexibility to cope with the gearing change and generally make driving a bit more pleasurable (particularly going up hill!) installed a bigger intercooler and had the fuel pump tweaked, and a hybrid turbo (and on 235/85/16's). To clarify what I'm saying though there are two drain plugs on the LT77 transmission, separate and apart from the transfer case. 4 and 2. Doing again almost the same job as a year ago New heavy duty transfer case and gearbox from Winchester Gears for our Land Rover Defender 110 Puma 2. Sep 10, 2017 · Guys, I've got a new LT230 from Ashcroft with the ATB. See below to find the serial number : Defender Guide : Suffix A or B uses a FRC5428 (26T), not available cross drilled Aug 21, 2023 · Case fixings: Supporting the transfer ’box fully with the transmission jack, Ian undoes the transfer case to gearbox fixings. 667 box you have, b) its very sluggish and just wont pull over 55mph, then its prob a 1. syncrogearboxes. Apr 21, 2010 · Mike, have you done a gearbox overhaul before, please dont take me wrong, unless you are trained in GBs it can be a daunting task in that you need to be meticulous in setting things like float and use of verniers and micrometers etc. I would stick with a defender box Sep 27, 2017 · Transfer box types. There are six: two from the front, four from the rear. I replaced the rubber/plastic lever and cut an M12 thread into the shaft. I pulled fuses and replaced them. Jun 13, 2015 · Hi, I've looked in the various guides for dropping the transfer box on a 110, and most of them recommend removing the drivers floor panel. 23. 2 box but all the main g box ratios are different anyway so you cant really make a direct compairson. Clutch: Here, here and here. 4 by LOF Clutches. Feb 5, 2008 · Most transfer boxes are 1. It turned out to be an easy job. …And remove the drum. 5 n/a deisel, or the v8 with a 1. Remove the breather pipe from on top of the transfer box (possibly 13mm). It was leaking like a sieve at the front plate. You also have to fabricate some kind of cover for the levers. Jul 14, 2015 · Quick video on how to remove the rear output bearing on a Land Rover LT230 transfer box. Transfer Box 1. com/t/primerGetting a scruffy heater box. Jul 29, 2012 · i have fitted a 1. THE NUTS ARE 9/16" NOT 14mm - it makes a big difference! Remove the propshaft and you will see a large nylock nut in the centre of the drive flange. Nov 11, 2009 · Mine's a 110 (previously with 2. Then undo the 3 nuts that secure the mounting bracket to the chassis so that it will completely drop away from the transfer box. May 2, 2021 · I have a suspicion the previous owner replaced the transfer case with a unit from a Discovery. 28D309143E to 551442F = 1. May 16, 2024 · transfer box removal is only a two man job if you are men of a certain age . Out and down: Ensuring it is supported, Ian pulls the transfer case towards the back of the vehicle to release it from the gearbox. My truck is a 94 D90. In hindsight the only thing I would do is loosen the bolts between the gear & transfer box some of these were bloody tight. I have a leaky transfer box that needs looking at and believe oil coming out of the engine rear crank shaft bearing (have oil coming out of the bell housing wading plug hole). There have been several incarnations of the LT230 transfer box since it was first introduced on the pre-Defender One Ten model to provide permanent four-wheel drive via its Jun 14, 2012 · I sat in the truck. Sep 19, 2006 · I've done the job myself on my 200Tdi with LT77 gearbox and LT230 transfer box. Specifically for a D1, although I assume the D2 is similar. 6 box, however if you do a lot of miles and need better top end at lower revs then consider a 1. In the tech archive, there is also an o ring 'bodge' that works quite well, To do the o rings properly, you have to remove the intermediate shaft and then set it up again properly which will involve stripping bits of the box. R380 Development. 4 TDCi This is how i dealt with myLand Rover Defender TD5 R380 Gearbox and LT230 TransferBox Removal Part 2. oil on the bottom of the handbrake drum oil spots on the rear window etc, however upon close inspection it is not EP90 oil but is ATF DX3 oil, and seems to be coming from between the main gearbox and the transfer case, I know from searching the forum that I can change the seals in the May 12, 2020 · This is how i dealt with myLand Rover Defender TD5 R380 Gearbox and LT230 TransferBox Removal Part 4. When free, he then lowers it. A unique type of grease, grease Weicon TL7391, must be applied to the transfer case input shaft spline when installing the transfer case. The crossmember under the box has to come off of course. Jul 18, 2024 · Looking for a transfer case for your Defender 110? Atlantic British offers rebuilt transfer cases, with charge, including this one for the Defender 110. Please always remember to Subscribe, Rate and comment, Feb 18, 2018 · The transfer case lever simply pulls off. 2 Tdci (2012 - 2016) Articles. The on-car techniqueLT230 overhaul kits and bearings available at ou Oct 27, 2009 · I've stripped the LT230 transfer box. So now on the lookout for a transfer box. 2's (better cruising speed at lower revs) and 110's had 1. May 12, 2020 · This is how i dealt with myLand Rover Defender TD5 R380 Gearbox and LT230 TransferBox Removal Part 5. Dismantling a damaged Land Rover Lt 230 tranfer box, - Q SUFFIX(stands for quiet - later type units) swapping casings and shimming the beast correctly. transfer box output flange for reassembly. To assist in the use of this manual the section title is given at the top and the relevant sub-section is given at the bottom of each page. 003 t/box. 1. 8HT This is how i dealt with my Land Rover Defender TD5 R380 Gearbox and LT230 TransferBox Removal Part 1. any help much appreciated. Loosen the filler first - clearance is tight as it's tucked-up 10cm North West of the output shaft and gives an access issue, as it's tight to the handbrake drum. Feb 22, 2008 · Take off propeller shaft universal joints at the transfer box end; remove both linkages for the high low and diff lock then remove at the transfer box end. Handbrake drum retention screw removed. #landrover#defender#LT230. My mate put one in his 90 (it was cheap) and quite likes the positioning of it but you are unable to fit a middle seat and will probably have to make your own cubby box. Aug 16, 2012 · Undo the single nut underneath the bracket, then get your trolley jack and jack it up to the underside of the box to take a bit of weight. The seal is ICV10000, should be the same for all LT230's. 2 failed and had a mpi 1. fitting a larger more efficient heater matrix to it with som Dec 9, 2008 · After removing the Transferbox and having new gears installed (due to a technical hiccup on removal) I had to have brand new gears popped into the Defender TD5's Tranny box housing. 67 litres (Non-TD5 models) 2. I have been losing some oil from the front output shaft area of the transfer box on my 1997 300tdi 110 of late and therefore figured it is probably time to renew the oil seals on the output shaft. 2-1 box third gear is about where 5th was with the 1. If so, leak is originating from transfer box. There is an internal magnet that is put there to scare those that don't know better . I then cut off the knob. It took 2 hours with a drill, punch,tap, magnets and tweasers to remove the remains and locate the now missing magnet in the transfer box! Mar 13, 2007 · Newbie help. paypal. Mar 22, 2016 · The case gives you an additional selectable gear reduction between the trans and the LT230 T-case, so you would have high, low (3. remove the x member, remover gearbox mounts and pivot the t box in place on mounts-gearbox pulls out. Thread starter english111; Start date Nov 20, 2019; Land Rover Defender MY07 Workshop Manual Complete (dragged) 2. I measured the depth of the thread on the knob and cut off that amount of plastic cover. Adapter, Wrench. 9. In this category we have 2 options for the LT230 transfer box. Very difficult for a first time from a manual and not uncommon in these cases to have the box in and out a few times before getting it right. Disconnect wiring for the speedo, reverse switch and diff-lock. Remove 4 central bolts from transfer box bottom cover, move hoist into position and secure adaptor plate to transfer box. TRANSFER BOX OVERHAUL MANUAL This transfer box is fitted to the following models: Serial No. Transfer box = standard LT230 Jun 3, 2012 · I knew then it had just snapped off in the transfer box, I tried gently removing it, but just got half of the thread. I plan to remove the t/case to inspect the output shaft as well. The only 'special tools' needed are a bearing puller (to remove the bearings from the differential, input gear and output shafts), some good circlip pliers and a steel drift. Jul 1, 2016 · Put some 205R16s on your Defender with a 1. - I did both props at same time. The transfer box is suspended on the studs at the back on the black strap. I don't know if the box is original the motor has done 175k. Oil needs ti be drained. Once removed I then split them, once all the bolts are undone the transfer box just slips off no need to remove anything else. Needed to haul a boat on a trailer, etc. This video is sponsored by Syncro Gearboxes: http://www. Dec 5, 2008 · We have this 06 Defender 90 with a TDI, manual gearbox, locking differential etc. Is it possible to remove it without touching the floor? I've got LPG tanks secured to the floor panel and an x-eng pendal lock so would rather avoid it if pos steering box; engine oil; full flow oil filter gearbox oil; transfer box oil; front and rear axle oil; propeller shafts clutch pipes and unions; pas pipes and unions; exhaust system steering box and suspension; steering ball joints; shock absorbers towing bracket; engine and transmission mountings road test; endorse service record report any Feb 20, 2021 · Lifted my 300TDi, gear & transfer boxes out as one lump last year. Remove the off side transfer box mounting. I am still young enough that i just pull it off and lower it onto my chest, and then bench press it back into position to refit. My shop got that fixed but we still have a small leak coming from one of the bolts that holds on the bottom plate. e. Prefixes 14D, 15D, 20D, 26D, 27D, 28D and 30D - Range Rover Classic Publication Part No. Which of course in this baby is 4 HI. rubber to chassis crossmember. The first pic posted shows only the drain plug for the extension housing has been removed. , Land Rover transmission and other transfer cases & hardware online at RoverParts. 43. Dave Part 1. Mar 31, 2007 · Naz, I've started to prepare my transfer box for removal today as the input shaft seal is leaking, so I thought I'd just remove the transfer box only and do that. LOF Defender MT82 EXTREMEspec output shaft kit for TDCI 2. Please always remember to Subscribe, Rate and comment, Tightening Torques: Gearbox Drain Plug: 50nm Gearbox Filler Plug: 35nm Transfer Box No Photos here, you need a half-inch square drive for fill and drain plugs. 5TD) now with a 200 TDi. Then drop out transfer and hook out seal to replace. The main reason is to install the new g/box breather fitting for Nugget's new 5-port breather. LRL 0081ENG - 2nd Edition Published by Rover Technical Communication Apr 22, 2017 · We replace a broken oil seal in the LT230 transfer box on Nisse's Land Rover 90 V8. pdf. Not too bad as long as you can manage the weight. 4. Jun 1, 2023 · Removal of the LT230 transfer box continues out of the Landrover defender 110. 38 litres (TD5 models) Transfer Box Capacity Jun 30, 2020 · I used ratchet straps on the transfer box and chassis and lowered each piece down after separating them . My plan is to check the level of oil, drain anyway, remove bottom plate and inspect. 192. Please see part Nov 1, 2015 · A mate has suggested that there us a bronze bush that separates the gears in the transfer box and they can wear leading to the gears touching. Prefixes: 20D, 22D, 32D, 43D, 47D, 56D, 57D, 58D, 59D, and 60D - Defender Jun 20, 2010 · How do you top up the oil in a defender 90 gearbox and transfer box? and is the same oil suffient for both? regards JC Last edited: Jun 20, 2010 wiltshire landyman Aug 25, 2019 · All, Looking for a write-up on LT230 removal. 2 defender pumas. Feb 27, 2014 · To cut a long story short, approx 3 litres of gear oil poured out. Jan 23, 2011 · When fitting and removing a gearbox, and/or transfer box from a defender type setup do you remove the rubber mounts before attempting the task?? I've always found it a pain in the arse with them on (almost impossible!) however when putting the mounts in first and then trying to bolt a box onto th Aug 10, 2010 · Sounds like then, either the splines on the output of the gearbox (into the transfer box) or the middle of the clutch plate has broken (i had 2 go in my old 300 110) (OR, unlikely, you broke a rear drive flange AND a front one/CV joint all in one go, which is why you'd still not move even if the difflock is engaged, but highly unlikely to be this) Soooo. I tried to have this be a minimally invasive removal with bare minimum removed. 222. 4 110 County Utility (possibly the last of Jun 3, 2008 · Puma is a 1. View attachment 152459 Not a brilliant picture but may give you some idea . that means opening up part of the dash board? then proceed to undo the screws to finally get to the matrix. 2 tdci hardtop xs 3. This is our design to a common problem on the Defender TDCI coupling shaft between the gearbox and transfer box, Designed as a one piece solid shaft conversion, this design prevents wearing, total loss of drive and 'clunking' on the Defender TDCI drive train! Designed to replace the Standard parts TUD500020 Mar 5, 2011 · Hi all. 4's - commonly found in 90's. Jan 2, 2019 · Hi all , I'm rebuilding a 300tdi 90 and fitting a disco auto gearbox and I'm after a bit of help . Nov 21, 2007 · Thanks everybody. Then the plug is replaced and tightened to 30 Nm. 7. No other oil must be used in the transfer case. It seems locked in HI. Sep 6, 2007 · Today I am mostly trying to fit a defender transfer box into my discovery All was going swimmingly until one comes to actually remove the old transfer box, as there isn't quite enough room to get the transfer box off the outputshaft from the main gearbox before it hits the floor at the back. 2. Seems that the differential in the transfer box of Land Rovers is a weak point. com/britresthttps://www. The input gear for the LT230 transfer case was EDMed by Buck (Buckon37s) out to 32 spline GM. May 23, 2013 · However, if you do need to remove the drive gear and the housing is stuck, the only way ive found to do it without damaging the housing is to remove the complete rear output housing from the transfer box so that you can get to the back of the speedo drive to tap it out with a punch. Then I could bolt the plate direct to the main box through the 8 mm holes and to the flywheel/clutch housing through the 10 mm hole, and using long bolts and 3 nuts on each you can ajust the level of the plate. Your jack is doing its job instead. You will need to drain the transfer box of oil because the lowest bolt holding the gearbox and transfer box together goes through in to the transfer box below the oil level. Dave Jun 22, 2009 · A slight hi-jack but still transfer box related: I have a knackered transfer box (LT230) that I would like to rebuild as a spare. I'll be doing the axles next, but that looks (hopefully) a lot more straightforward Defender "Puma" 2. tight, as these holes are tapped into main transfer case. We removed it through passenger door. Because of this it is essential to look after the box to ensure power is correctly applied to the front and rear of the vehicle from the transmission. 5:1 and my series diffs are 4. To remove the transfer box is fairly easy however, it is just lots of little jobs list (but possibly not exhaustive) below. May 1, 2018 · Step 15: Before the transfer box was removed, the drain plug was removed and any remaining oil was allowed to drain into a container to be properly disposed of. However, due to the state of the bolt heads and nuts being ( previously) slightly rounded and now a lot more rounded i would like to replace at least the nuts if not the bolts as well. We supply the LT230 geardrive transfer boxes as well as the Borg Warner chain drive transfer boxes as fitted to the RR Classic from 1989 onwards and the P38A or "New Shape" RR. CAUTION: Care must be taken when turning the transfer case over. This was done by one person in one day, to give a reference on time. . I have a 90 with what at first appears to be a classic transfer box oil leak symptoms, i. 2 conversion DONE 238bhp and 707nm torque and thats just the start ;-P hybrid turbo in build -done ready to fit ashcroft atb in transfer box 6 speed auto in build Sep 26, 2017 · This coming long weekend I'm planning to drop the gearbox and transfer case. ly/3feE6tJ*In this video, we show you how to replace the transfer case output shaft s Sep 21, 2011 · Things to remove: speedo cable, e-brake cable (remove and push through the floor), dual vent lines, t-case temp sensor, solenoid plug, linkage for low-high, pass side frame mount (I ended up removing the drivers as well to lower tranny), obviously both driveshafts and the exhaust system y-pipe and cats, o2 sensors, and the 6 bolts securing the Mar 24, 2008 · There's a housing on top of the transfer box, four bolts retain it IIRC, easily visible with the centre cubby/centre seat and plate removed - simply remove the housing, then remove the shaft and tighten the grub screw up, refit shaft ensuring 'finger' fits into recess on the selector rod and do the housing back up. Havnt got any pics of prop shaft removal, but its a 9/16 spanner, or 14mm in new money. Aug 27, 2014 · All indeed true. Remove the two propshafts, dismantle the handbrake drum, remove the chassis crossmember (this part was a bit of a b**ch to remove), remove the bell housing nuts, support the engine, withdraw the gearbox and transfer box. For all other information regarding adjustments and removal of oil seals, consult the Repair Manual for the model concerned. me/britrest2018Your support is appreciated!If you have a Defender/Tdi problem and do not know how to fix i Mar 3, 2020 · I currently have a 3. Remove transfer box to inspect mainshaft collar. Mark front propeller shaft drive flange and. the bolts are 8. 6-1 box as it was drilled and tapped for the 110 handbrake bracket. and when done, pray hard that you don't bend anything when you put it back or you'll have a leak again. Cheers, The oil used in the transfer case is specially developed and contains unique additives, which enhance the transfer case operation. 0 transfer box (used on the early 3 speed auto RRC) they'd be having similar issues to a Defender running 1. 104 KB · Views: 124 Jul 20, 2008 · The filler plug on the transfer case is also a level plug, so providing that the vehicle is on a reasonably level surface, fill with EP80/90 oil until it starts to dribble back out of the hole. A transfer box with the suffix A or B will only accept the earlier 26th tooth, non cross-drilled type (FRC5428). Defender (2007-2016, Puma) Transfer Boxes ⚑ Fast delivery worldwide Payment options including PayPal ⛽ British car experts ♚ 01522 568000 ☎ 1-855-746-2767 Special Offers Get ALL of the latest offers & promotions delivered right to your inbox! steering box; engine oil; full flow oil filter gearbox oil; transfer box oil; front and rear axle oil; propeller shafts clutch pipes and unions; pas pipes and unions; exhaust system steering box and suspension; steering ball joints; shock absorbers towing bracket; engine and transmission mountings road test; endorse service record report any Nov 27, 2015 · Hi, the web list is a simplified version : 28D, sx B = 1. Is it a hard Gearbox / Transfer box removal If I were to remove the gearbox / transfer box via 2 or 4 post ramp, is it still necessary to lift up the transmission tunnel lid between the seats? I only ask as I have mounted by aux fuse boxes in a mud locker there, and have drilled the lid to do it. 6-box (ish). Remove the 19 transfer case bolts. 24. Remove nut securing transfer box LH mounting. First things first, the oil needs to come out. PART(S) NOTES: This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct. Torque Specs - Defender Puma 2007-2016; Paint codes; Axle Codes; LT230 Input Gears; Differential flange and oil seals; Wolf types; Servicing Schedules. May 28, 2023 · Removal of the LT230 transfer box out of our defender 110. 208. Jun 10, 2016 · This is an LT230 transfer box, but the principle is the same on any of transfer boxes used on the beam-axle models. Ensure joint faces of transfer box and main gearbox are clean and guide studs, LRT-41-009, are fitted to extension case. so i gather this if i heard your right, figure out how to remove the entire heater box by removing the 2 bolts and nuts that hold it to the bulk head. When I measured the oil taken out, I only measured 2 litresit must have been a bit shortI'll be keeping an eye on it over coming weeks. 64). Remove 2 bolts, withdraw clutch slave cylinder. Jan 17, 2014 · To reduce heat stress on my Land Rover Defender transfer case during periods of heavy offroading, I installed a Global Roamer Transfer case cooling sump. 4 in my DISCO after my 1. now when you say 'wont go more than 55mph, a) is the engine screeming, if so its a 1. We can also supply replacement and upgrade Clutch kits as well as replacement Master and Slave Cylinders, Red Booster Servo Kits, Gear Levers and Hoses all available from Transfer box: Here, here and here. Ashcrofts can supply a kit (seals bearings etc) but I opened the case up and noticed a few of the gears are missing teeth. It's not an overly complicated job. If these areas require servicing Nov 2, 2018 · I mashed my LT230 transfer case and now I have to replace it. Remove 4 nuts and bolts securing chassis Apr 21, 2017 · With the 1. e if I also remove the radiator to ease the removal. May 31, 2021 · Hi, l have a Defender with a lt230 transfer box and unfortunately it has an oil leak that looks to be coming from Intermediate Shaft. The best part is it gives you an extra shifter to play with. Mar 5, 2011 · Hi all. Aug 20, 2020 · How do you remove and replace the FRONT Transfer box input bearing, can't seem to find any info on this? Have removed prop shaft, bolt flange, dust cover, seal and cir clip Jan 22, 2013 · I put the truck on 4 ramps, open both front doors wide and tie them that way, take out the floor & transmission tunnel, remove the centre cover on the seat box, then put my chain hoist on an 'A' frame through the front doors, whip off the prop shafts, remove the exhaust and transmission mounting brackets, lift the transmission slightly, put a block of wood under the flywheel housing, lower Jan 22, 2018 · Best ( easiest ) way to disconnect the linkages from the transfer box (lt230/r380) on my defender? Have looked in the lr workshop manual but that only deals with the stripdown and rebuild of an already removed unit. 25. Also looking for advice for my first attempt. Details are below: Gearbox = standard LT77. patreon. I don’t have an engine hoist . com. The main case plug is still in there. I live in western Kenya (from Virginia) and tools and supplies are at a premium. Worked a treat, unit was lifted, swung around to the new chassis and in position inside of 30-mins (mind you, having no body fitted did help a little bit!). My Defender 90 was built in 2011 and has the 2. Now the top half including the magnet was wedged in the hole. Evidently the interlock system includes the transfer case as well as the automatic transmission. Replace the plug and lower the vehicle back to the ground. I once replaced the speed sensor with a unit out of a Discovery and it plugged right into the transfer case (the dash speedometer is a digital VDO unit). 6's. A transfer box with the suffix C onwards will accept the later cross-drilled type. One in the Land Rover transmissions family. cover, move hoist into position and secure adaptor plate to transfer box. It has to come off for the intermediate shaft o rings and the input seal. I tried every gear on the transmission individually. Step 13: The axles and transfer box are filled with oil until the fluid just begins to overflow out of the filler hole. 2/2. SPECIAL TOOL(S) 303-1069. Please always remember to Subscribe, Rate and comment, Defender (2007-2016, Puma) Transfer Boxes ⚑ Fast delivery worldwide Payment options including PayPal ⛽ British car experts ♚ 01522 568000 ☎ 1-855-746-2767 Special Offers Get ALL of the latest offers & promotions delivered right to your inbox! Technical . PYF500010 - Washer for Output Shaft on Transfer Box (Fits Front and Rear Flange) - Defender, Discovery 1 & 2 and Range Rover Classic & P38 (Priced Individually) Transfer Box Filler: 30nm Transfer Box Drain Plug: 30nm. Feb 28, 2010 · This is intended as a brief description of removing the engine along with the transmission and transfer case as one big lump. Makes a horrible whining sound when you come off the power in gear so I think it needs to go anyway. Apr 16, 2009 · 1. Thi Mar 25, 2020 · Today I am doing the same for the t-case, but am waiting for a 1/2 inch drive socket to arrive to remove drain plug first. A 1/2" drive ratchet is the right size to remove the plug. co INSTALLATION. 4 transfer box spare,its better like you say , if ya running bigger tyres. Remove 4 central bolts from transfer box bottom. Adjust hoist to take weight of transfer box. Aug 21, 2016 · I have taken many heater boxes out of 90/110 landies, however I have never taken one out of a Td5 defender fitting with air conditioning. 667 t/box with the 2. You can drop the unit easily on a transmission jack but it is often easier to remove the transfer box first, then the main box (definitely worth it on the Puma since it allows the notorious splined shaft to be inspected). It’s slow, so meanwhile other tasks are carried out underneath. Once back on remove threaded bar and fit bolts. With assistance, release the transfer case and secure with the rear face of the transfer case facing down on a flat surface. The R380 was introduced in 1994 with the suffix J which was a significant improvement on the LT 77 it supercedes> Differences included a steel oil pump (as opposed to the LT 77 fibre one), an additional 2 support bearing, used on the layshaft and the mainshaft, wider gears, bigger diameter synchro rings, synchromesh on reverse and a longer mainshaft spline. Nov 5, 2019 · A quick guide to show the tools and techniques used to remove the output shaft cup that commonly wears on both the 2. Thanks. T Aug 20, 2011 · Hi Folks, just looking for some quick advice from any gearbox gurus out there. Aug 14, 2006 · Its transfer box off, remove bolts and replace with studding to avoid straining o/p shaft of the main box. I could NOT get that little sucker to shift. The key could now be removed. Step 16: Next the transfer box was supported on a suitable transmission jack, and the eight bolts securing the transfer box to the main gearbox removed. The gearbox had one tooth missing so so it's had some pressure at some point. It is also worth noting that the military spec LT77 main gear-box has a slightly lower 1st gear than standard boxes. Recently installed Ashcrofts LT77 gearbox and transfer box with 1. I've looked up pictures of Defender 90 parking brake systems and they don't look like my setup. 4 Puma engine - my handbook gives oil specs and capacities for everything except the transfer box - I have read somewhere that the capacity is around 2. 44. 2:1 Defender 90 V8 w/o Interlink Model #: IAB500105R Browse through the interactive Land Rover Defender Gearbox Diagrams to find parts for LT77 - 5 Speed manual, LT85 - 5 Speed manual V8, R380 - 5 Speed manual, ZF - 4 Speed automatic, MT82 - 6 Speed manual Jul 22, 2018 · Easiest way to re fit is to slide transfer box along 2 lengths of threaded bar approx 200mm long fitted in place of 2 bolts, it serves as a guide and saves the weight of the box resting on the oil seal and causing a leak further down the line. Browse our range Gearbox-Transfer Box Jaguar or Land Rover - Huge Savings Fast Delivery Expert Advice LAND ROVER DEFENDER ALL 4 CYL Nov 4, 2008 · yes, that's the one in the picture. Back off the handbrake cable and shoe adjuster. The on-car techniqueLT230 overhaul kits and bearings available at ou Mar 1, 2018 · Step 12: Fresh EP90 gear oil is pumped into the axles and transfer box using this transmission oil filler. seal track condition, and front face of transfer case for porosity. At first i thought that oil had migrated from the main gearbox but that too was full. Disco's had 1. Jul 22, 2016 · Rust Stabilising Primer from Buzzweld http://buzzweld. 211 (Q gears) Aug 24, 2013 · Maybe this is obvious to others, but it took me a couple of times fighting the transfer case to figure it out: 1) Remove the four central bolts in the bottom cover of the transfer case. The oil levels were correct about 6 months ago when I last had the boxes off. Looking at the LT230T for the first time. Jun 22, 2011 · Now due to the fact that its a 1987 csw, it would originally either have had a 1. I tried the transfer case — the beep ceased. Remove cubby box, and middle seat box cover plate. I had to change a UJ on my front propshaft recently and after a lot of cussing and severely scraped knuckles i managed to get the PS out. Prefixes 20D, 22D and 32D - Defender Serial No. 8. 5 motor and LT77 gearbox which came out of a low miles 93 Defender and am looking for an LT230 transfer box to complete the set. Fits Defender 110. Firstly what's this for it's on top of the auto box And secondly am I correct in thinking that this is the kick down cable , if so can I use it in the conversion as it's a Disco one or do I still ne 24. Please always remember to Subscribe, Rate and comment,. Dec 9, 2008 · After removing the Transferbox and having new gears installed (due to a technical hiccup on removal) I had to have brand new gears popped into the Defender TD5's Tranny box housing. This then allows you to push the propshaft up (towards the oil filter) and create space to get a socket on the Transfer Box end nuts. kepgolcfiedujjrlqqtkwthifrterqsowxooqawztpmrwpx
Defender transfer box removal. html>wztp
Defender transfer box removal. Remove 4 central bolts from transfer box bottom.