Changing Transfer box to a Disco one

I am thinking of changing my transfer box to a Disco one as I have heard it would give my Defender slightly longer legs for motorway work.
I would presume if I keep it the same 200tdi I shouldn't have problems with handbrake connections etc. What I would like to hear is any comments for guys that have done this. Does it give the Defender much longer legs on the motorway. Would you do it again or stick to the standard defender box.
Does it make much difference to fuel economy.
My Defender will cruise happily at 70 mph. I did a 2000 mile trip from the south of France to the UK and back without any problems.

I did that when I fitted a 200. No problems at all, the ratios seem just right, although I'm running on 205/80/16 tyres. Larger will push the ratios up, so depends on your tyre size and if you will be towing. I wouldn't change back. I did make the mistake of fitting the box first, as I had read that the disco linkage could be used. Maybe you can, if you tie the handbrake cable in a knot. Made drilling and tapping the casing fun!

You will have to modify the handbrake connection. I used the original linkage, drilling and tapping two holes in the transfer box casing. It's obvious where when you hold the linkage in place. Enjoy

Just done that on my 1994 300 Tdi (3 week's ago)

If honest i haven't quite got used to it (Defender is not my daily drive) and too soon to make a call re: fuel economy.

PLUS

- Certainly cruises more comfortably at 45 - 60mph
- Has the legs to go faster - but I don't in the Defender
- Engine noise less deafening!

NEGATIVES

- Am changing down more often
- 3rd is sometimes slightly too low when 4th is slightly too high


Do I regret doing it - no. Am I delighted I did - not really either. On balace if I were doing a lot of motorway driving I'd say 'go for it', if it's more around villages/towns I'm less convinced

I have a 300tdi auto with the disco transfer in a 90 on 265/75 r16 , its still edis so a couple of brke horsepower more , but not good for towing , as it drops out of TCL , OK for m/way solo , but am thinking of going to 1.4 box , rather than smaller diameter tyres as on a disco . JMHO

A Good swap
I changed mine in my 200tdi a couple of months ago and it makes a good difference on the motorway. Not sure the fuel economy is any different but can now here the radio at 60_70.
You need to drill and tap 2 holes for the handbrake or drill the bracket so the original hole on the box can be used.

Did my 300Tdi 110 CSW over a year ago when I did the clutch.
that ended up with a gearbox rebuild including a new layshaft. In turn the input drive on the lt230 was shot so got a second hand disco one.

Definately less noise on motorway and noticed a marked improvement in fuel on long motorway runs.
However I find that 30mph is the speed at which I change into 4th now.
that in turn means going up very slight incline I have to change down to 3rd or following a slower than 30mph(28mph) person I have to change down.
this can be annoying keep changing up and down.
Having said that though the engine has done 235k and may now be as lively as it should be.

Would I change back - No

300Tdi on a R380 to a Lt230.

I have a recon lt230 1:2 and recon lt77 in my 90 from Ashcrofts.

On the old 1:4 transfer box I'd be revving the nuts off the engine at 45mph in 5th

Since the 1:2 I can sit at 50/55mph in 5th at comfortable revs and a lot less cabin noise

I've had it up to 70mph a few times to overtake, which it doesn't struggle with, but I don't want to push it.

The 1:2 box does effect pulling away a bit as in I have to give it a bit more throttle, so if you tow then you might want to consider that and that's on 235/85r16's

Fuel economy has improved too, getting 32mpg(ish) on the motorways

Thanks guys for your feed back. I will be doing a trip across Morocco in the not too distant future so I think I will leave it till I get back and have a rethink then. As I mentioned earlier it will cruise quiet happily at 70/75 mph all day and does it regularly.