disco transfer box

today i put a disco transfer box on me 90 (that has a 200tdi)
turned out to be a right bastid of a job, but got there anyway.
thing is in low box it wines its head off.

jumped out of high box into nuetral, but i think that just needs ajusting.

any ideas why it wines through all the gear in low box?????

thanks.

Probably wear and tear, mine whines and also rumbles on overrun. It also clunks because it is well worn and I need a new one.

no it aint that, as it were fine on the dicso it came off.
think ive done something thats made it tight, front prop were very tight whe i put it back on !!!!

DO NOT DRIVE IT if the prop-shafts have bottomed out longways!

You WILL wreck something expensive.

Sort it.

CharlesY

Sorry to hear you are having problems with this, I am thinking of doing the same conversion but how do you deal with the gearstick/ transfer box lever being the other way round to the defender layout? Have you tried the new box at high speed yet, and does it make a real difference?
Cheers

darius said:

Sorry to hear you are having problems with this, I am thinking of doing the same conversion but how do you deal with the gearstick/ transfer box lever being the other way round to the defender layout? Have you tried the new box at high speed yet, and does it make a real difference?
Cheers

Click to expand...

I've swapped mine for a disco 1.22 and the V8 is a lot better with it. It'll pull 35 in first and 55 in second but thats with a petrol which has more revs than the diesel.
Not been over 60 yet but it's about 2500+ revs at 60 I think.

darius said:

Sorry to hear you are having problems with this, I am thinking of doing the same conversion but how do you deal with the gearstick/ transfer box lever being the other way round to the defender layout? Have you tried the new box at high speed yet, and does it make a real difference?
Cheers

Click to expand...

havent got that far yet, going to have another look at it tomorrow.

i swaped mine for a disco one and had no problems at all, now get 33MPG with a full roof rack on a loaded 110 over a 170 mile drive at 70MPH

check your rubber gaitor on hi/low lever, mine did the same and it was the rubber

got it sorted know!!!

took front prop off, jacked the back wheels off the ground spun the a few times, ajusted the linkage, put it back together.
whent for a drive, no whining, high/low/diff work fine.
and im well pleased with it, think it will be good on the back roads and good on motorways.

darius said:

Sorry to hear you are having problems with this, I am thinking of doing the same conversion but how do you deal with the gearstick/ transfer box lever being the other way round to the defender layout? Have you tried the new box at high speed yet, and does it make a real difference?
Cheers

Click to expand...

Put a 200tdi disco one into my 200tdi defender and everything was the same apart from the handbrake linkage.

That said because my defender linkage was junk I managed to "s" bend the handbrake cable onto the disco linkage (just) and it's fine.

Now with the 1.2 ratio and 33" tyres it cruzes lovely at 70

spuddog said:

Put a 200tdi disco one into my 200tdi defender and everything was the same apart from the handbrake linkage.

That said because my defender linkage was junk I managed to "s" bend the handbrake cable onto the disco linkage (just) and it's fine.

Now with the 1.2 ratio and 33" tyres it cruzes lovely at 70

Click to expand...

i have the same problem, the handbrake linkage!!
the one off me 90 box wont fit on the disco box.
is that all you did to get the cable to fit????

ISTR reading you have to drill and tap new holes to fit the defender bracket to the disco box...

pete23 said:

i have the same problem, the handbrake linkage!!
the one off me 90 box wont fit on the disco box.
is that all you did to get the cable to fit????

Click to expand...

Yes it just about makes it. I managed to connect the cable directly to the disco transfer box lever bracket setup.

I do have a td5 handbrake lever though, so I think that gives me more to play with on the cable length.

If you do not fancy drilling and tapping the holes (careful its almost technical) undo the rear bearing support ally casing of the transfer box and shaft and swap them over. The holes for the hand brake are then also swapped over. All you must do is refit a new gasket. This is good if your old transfer box bearings are in good nick

jai_landrover said:

If you do not fancy drilling and tapping the holes (careful its almost technical) undo the rear bearing support ally casing of the transfer box and shaft and swap them over. The holes for the hand brake are then also swapped over. All you must do is refit a new gasket. This is good if your old transfer box bearings are in good nick

Click to expand...

to drill and tap (no where near technical) i would have to remove transfer box again???
i assume the "rear bearing support" is the casing behind the handbrake drum??

pete23 said:

to drill and tap (no where near technical) i would have to remove transfer box again???
i assume the "rear bearing support" is the casing behind the handbrake drum??

Click to expand...

You can make the cable fit as it is, plus the adjustment is much lower down and easier to get to...which is nice.

No can be done in situ if careful, I did mine. do not drill to far in and you wil need a finnishing tap to get the threads square right to the bottom of the drilled hole.

Drill and tap could be done in situ yes - I tapped mine on the garage floor in about 4 minutes. Took EVERYTHING from the original LT230 for the brake and bolted it all onto the disco LT230.

Someone asked about the linkages being the wrong way round, the transfer box linkages (as in the actual box itself) are identical, its the shifter setup on top of the main box of the disco that is different, the hi low lever doesn't even come out on the change, it's bolted to the main box.

So all you do is swap them round, and connect up the linkages which may need tweaked so it sits well in hi and low without being on the edge.