How hard is it to rebuild a 200tdi transfer box

payydg · Sep 16, 2015

I've got an old transfer box off a disco. Bought off eBay a couple of years ago. Apparently was working at the time.

I'm thinking of having a go rebuilding it with a cross drilled input gear etc.

There're some great video on the Land Rover toolbox you tube channel.

How difficult is this? Am I going to just end up with a box of broken bits. I know gear box rebuilds are very tricky but I hear the transfer box is a lot simpler.

Im no mechanic but I'm becoming reasonably competent.

Zed. · Sep 16, 2015

I rebuilt a spare for my '94 but used it in my '92, I didn't take it completely apart as when partially striped the intermediate shaft / gears and centre diff are visible (maybe worth pulling diff as the cross pins can have wear??) but worth fitting a new input gear & output bearings as these are in bolted sub-assemblies.

Easy to do if you have sufficient tooling, a press really helpful for the input taper bearings and I re used the ones in mine as they were fine although not expensive new, the output bearings are ball races and are again cheap and give an excuse to change the seal & maybe the flange if it's worn?

Rich.

payydg · Sep 17, 2015

Zed. said:
I rebuilt a spare for my '94 but used it in my '92, I didn't take it completely apart as when partially striped the intermediate shaft / gears and centre diff are visible (maybe worth pulling diff as the cross pins can have wear??) but worth fitting a new input gear & output bearings as these are in bolted sub-assemblies.

Easy to do if you have sufficient tooling, a press really helpful for the input taper bearings and I re used the ones in mine as they were fine although not expensive new, the output bearings are ball races and are again cheap and give an excuse to change the seal & maybe the flange if it's worn?

Rich.

Thanks mate. Great info.

I don't have a press but may get one. What sort of press would be suitable?

How hard is it to rebuild a 200tdi transfer box

payydg

Well-Known Member

Zed.

Well-Known Member

payydg

Well-Known Member

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