Removing Transfer Box

Well my disco started making a **** noise Friday and upon investigation it seems several teeth are missing from the gears in the Transfer box. I have started to remove it but the manual isnt very useful/descriptive.

I have most of the bits going to it removed and am on to taking the actual bolts out that connect it to the box.

Anyone know how many there are ot any pics of their locations. I also havent taken the handbrake drum off, is this necessary? if so hows it done?

I searched back through posts to 2009 and couldnt find much except threads about oil leaks and not having diff lock

Thanks guys

6 all together 2 x from front backwards drivers side ,bottom one will leak oil if not drained easier to remove all of brake assembly ,will need levering to part from gear box

quite easy to get off i think theres approx 8 bolts and studs, some are accessed from the top, dont forget to disconnect speedo cable from behind hand brake drum, the drum can stay on but remove handbrake cable, then whilst supporting on a jack lever it from the gearbox shaft, fitting is hard work on your own and try not to damage the oil seal that goes over gearbox shaft.Oh its heavy and awkward to manhandle

you got 2 more than most, removing hand brake lessens wieght on the worst side,putting back can be helped with 10mm studding as guides and remember to check dowels,they are necessary but only 2

Thanks guys Good tip with the studding

is £150 a fair price for a 2nd hand transfer box from a breakers?

300 and td5 boxes are different, early transfer boxes did not have cross drilled gear in and wore output shaft

Last lt77 and transfer box I bought £50

if its 300 tdi and in good nick with a guarrentee for 3 months

I thought the 300tdi used the LT230?

yes they all do even td5 but 300 is better than 200 lt230 like for like ,but they change internally over time, overall ratio the same

jamesmartin said:

yes they all do even td5 but 300 is better than 200 lt230 like for like ,but they change internally over time, overall ratio the same

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also the lt230 suffix early b transfer boxes will not accept a cross drilled gear.