issue fitting a Romerdrive to 300TDI

PopaDom · Dec 5, 2021

afternoon all,

I am instaling a roamerdrive DS to my 300TDI defender.
however, I have hit a snag that I hope I am just missing something really simple.

the instructions state.
"reach into the aperture and remove the gear visible inside the housing. you will have to put the gearbox and transfer case in neutral and rotate the gear to remove it."

I can't seem to get the gear out, I've tried turning it clockwise as is shown in the picture and I have tried the opposite way too. it just not coming out. I have both the transfer box and gearbox in neutral and I can rotate the gear with my hand but no lateral movement.

am I missing something? is there a trick to doing this?
any ideas are welcomed.
Cheers Dom

Hicap phill · Dec 5, 2021

Is that the front or rear of the transfer box?

PopaDom · Dec 5, 2021

Hicap phill said:
Is that the front or rear of the transfer box?

That's the rear, behind the pto cover. Next to the drum brake. That gear is supposed to be removable. I know alot of people have successful fitted these roamerdrives so there must be something I am missing.

Hicap phill · Dec 5, 2021

PopaDom said:
That's the rear, behind the pto cover. Next to the drum brake. That gear is supposed to be removable. I know alot of people have successful fitted these roamerdrives so there must be something I am missing.

Thanks.
I don’t remember seeing that behind the transfer plate.

So should be on a bearing which just pulls out. Then you can get to the gear. Make sure you know which way you take this out.
I’m not near a transfer box till next weekend for photos if you have further problems

Hicap phill · Dec 5, 2021

Does you back plate look like this?

PopaDom · Dec 5, 2021

Hicap phill said:
Does you back plate look like this?
View attachment 253997

yes, it looked like that, but mine had six-bolt heads, it doesn't have what looks like a threaded rod with a nut on it at the 6'oclock position though, like in your picture.

PopaDom · Dec 5, 2021

Hicap phill said:
Thanks.
I don’t remember seeing that behind the transfer plate.

So should be on a bearing which just pulls out. Then you can get to the gear. Make sure you know which way you take this out.
I’m not near a transfer box till next weekend for photos if you have further problems

okay, that's a bit concerning then. as far as I know, I have a standard transfer box. it does have a bearing, you can see it when looking in, but there is no lateral movement and it turns very smothly.

Hicap phill · Dec 5, 2021

PopaDom said:
okay, that's a bit concerning then. as far as I know, I have a standard transfer box. it does have a bearing, you can see it when looking in, but there is no lateral movement and it turns very smothly.

I remember taking the plate off & pulling out that shaft.Fitted transfer box to gearbox then replaced the gear.
The 1 bearing sat in that rear plate.(like the instruction photo)

does your have that plate with the 2 counter sink screws holding it in place as per the instructions?

PopaDom · Dec 5, 2021

Hicap phill said:
I remember taking the plate off & pulling out that shaft.Fitted transfer box to gearbox then replaced the gear.
The 1 bearing sat in that rear plate.(like the instruction photo)

does your have that plate with the 2 counter sink screws holding it in place as per the instructions?

no just 6 bolts, it looks identical to the one in your picture, other than the at 6'oclock position. my Landy is Ex-military. but as far as I understood the transmission doesn't have any differences compared to the civilian model. the part catalogue doesn't seem to state anything differently.

I have emailed Roamdrive in Canada but I don't think I will get an answer until Tuesday, as they are 8hrs behind.

how easy was it for you to remove from yours? did it just come out fairly easily? you didn't have to use a gear puller or anything?

I have attached the part numbers and diagrams of the gears, they are standard as far as I know.

Hicap phill · Dec 5, 2021

Mine just slid out.& I replaced it the wrong way round

. Could only get 4/5 & reverse.
If you still struggling Friday message me & will go out and strip a transfer box down.
(I work away all week & won’t be back till Friday evening)
Where abouts in Oxfordshire are you?

Hicap phill · Dec 5, 2021

& that bolt at the 6 position holds a bracket for the handbrake cable

flat · Dec 5, 2021

That looks normal, have a look at my thread here which is the same as yours (also ex military)

https://www.landyzone.co.uk/land-ro...-spline-wear-on-an-lt230-transfer-box.226597/

try turning and pulling at the same time, I recall mine wouldn’t come out and then suddenly it did. If that makes sense…

mine is a 1:1.4 transfer box

PopaDom · Dec 5, 2021

Hicap phill said:
Mine just slid out.& I replaced it the wrong way round . Could only get 4/5 & reverse.
If you still struggling Friday message me & will go out and strip a transfer box down.
(I work away all week & won’t be back till Friday evening)
Where abouts in Oxfordshire are you?

okay, that's interesting. oh no that sounds like a nightmare!

I really appreciate the offer but If I don't get it sorted by Wednesday she will sit in the garage until I can get back down to my folks, unfortunately.

I was based in Bicester, but I sold my house and moved to North Yorkshire, we haven't sorted a place with a garage yet so, my Landy is very kindly being stored in my folks' garage until then.

I am down for a few days and I got the nod from the other half to buy the overdrive, I didn't wait for the dust to settle, I just ordered it!

kevstar · Dec 5, 2021

It should just come out ive only got a casing in the shed as I just rebuilt one a few weeks ago & binned the spare one, mole grips on the end & wiggle it and.or whack the outer casing with a rubber/nylon mallet. This is the later type with the modified hole in the shaft.

kevstar · Dec 5, 2021

Hicap phill said:
Does you back plate look like this?
View attachment 253997

Hey Phil what make is your disc brake, mine has a different spring set up iirc mines is x engineering.

PopaDom · Dec 5, 2021

flat said:
That looks normal, have a look at my thread here which is the same as yours (also ex military)

https://www.landyzone.co.uk/land-ro...-spline-wear-on-an-lt230-transfer-box.226597/

try turning and pulling at the same time, I recall mine wouldn’t come out and then suddenly it did. If that makes sense…

mine is a 1:1.4 transfer box

okay, we will try again tomorrow. your thread looks good, thank you I will have a read.

is there a straight forward way to check what ratio gears I have?

PopaDom · Dec 5, 2021

kevstar said:
It should just come out ive only got a casing in the shed as I just rebuilt one a few weeks ago & binned the spare one, mole grips on the end & wiggle it and.or whack the outer casing with a rubber/nylon mallet. This is the later type with the modified hole in the shaft.

View attachment 254005

okay, the mallet will be worth a try. hopefully we can get it out.

kevstar · Dec 5, 2021

PopaDom said:
okay, the mallet will be worth a try. hopefully we can get it out.

I stripped two & both fell out, if it doesnt come out I'll have romerdrive of ya

PopaDom · Dec 5, 2021

Hicap Phill and everyone thank you for your assistance. I will keep at it tomorrow and report back. hopefully with a positive outcome.

PopaDom · Dec 5, 2021

okay, so I have done some digging. I do have a 1:1.4 ratio gear set thankfully.

basically, you need to find your transfer box serial number. I found mine on the left of the transfer box just above the oil slump cover, under what I suspect to be a combination of road grim, half the Salisbury plain, and a bog i got stuck in a few years back! I didn't know it was there until I looked up where to check and gave it a scrub.

once you have it, look up the first bit against this chart I have attached. and that will tell you what your gear ratio is. mine is 22D so i have 1:1.4,

i found my info here https://www.shop4autoparts.net/technical-info/LT230-Transfer-Box-R-Type-T-Type/

I believe it is correct but if you are more knowledgeable and I am misinformed please say so. hopefully though, this will save someone some time if they stumble upon this.

issue fitting a Romerdrive to 300TDI

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