out put shaft too long???

Hi

I have seen a thread about this problem but after searching for an hour I can no longer find it.

I have had to change the gearbox (LT77) on my 1988 90 as the output shaft is worn. I found this out whilst changing the transfer box for a disco box.

Any way I sourced a gear box painted light blue that looks as though it is reconditioned.
I fitted it to the landy no problem but when I fitted the transfer box the box slid onto the output shaft but stopped short of the gearbox casing by about 15mm.
I removed the plate at the rear of the transfer box and removed the aluminium plate inside which looks as though it is a seal and then the box slid right on.
Can anyone tell me how to get around this problem????
The old transfer box does not have this inside but it looks as though it has leaked for the previous owner as the plate is fixed onto sealant.

aluminum plate inside rear pto cover is an oil screw oil is fed by it to mainshaft ,to fit an lt77 thread needs cutting off main shaft ,there was a big problem with the splines on mainshaft and in input gear wearing to the point drive was lost ,these oil screws were used as a solution at one time ,later with introduction of cross drilled input gears this did away with need ,box will run fine for years without either

Do you mean cut the thread off of the output shaft from the gearbox?
Will this cause any other problems?
How did this transfer box fit originally?
Would this box work and seal if I left the aluminium plate off

Many thanks for your response.

have you made sure the dowels are located correctly sounds as if you have dowels in both the gearbox and transfer box. this would make it not fully engage. remove transfer box rearward slightly check location of dowels make sure your not using 2 dowels for 1 hole and try again.

yes to fit oil thrower thread of main shaft needs cutting off ,this then makes any further work on gear box difficult as thread is used during stripping and rebuild for special tools ,oil thrower was an after thought fix for mainshaft wear,i first came across them on military boxes,it will run okay without it they are fairly rare ,as said cross drilled input gear in mid to late 90s did away with any need for them

I have not left the dowels in both as once I removed the pto plate at thr rear of the box the box slid on against the gearbox.

If I replace the input shaft with a cross drilled one could I leave the oil thrower off and if so will oil not leak from the pto cover plate?

in which case its redundant anyhow just leave it out ,its not fitted to many large o ring is part of oil thrower not sealing pto cover or bearing plate ,the only thing that matters is you use silicone if thats how it was sealed or a gasket if that between box and bearing plate pto to bearing plate doesnt matter which you use

oil thrower Redirect Notice

Are the input shafts in the transfer box easy to change?

I have seen a few threads about this but not taken a lot of notice maybe buster has a step by step guide?
Did the gearbox used for these oil throwers have a shorter output shaft
?

I was told this transfer box is from a disco that drove well before it was scrapped But the chassis had rotted.

Many thanks for your advice A day without education is a day wasted and also frustrating it appears every thing I touch on this landy is knackered

Thanks for the redirect this is interesting reading

It looks as though I need to have a look for the numbers on the box and take it from there.

Many thanks

if main shaft is worn so will be input gear ,as was due to lack of oil in splines ,cross drilled gear cures this ,oil thrower was earlier attempt to change input gear you need to do it before fitting transfer box if disco 1.222 ratio it is possible on gear box but needs pulling bacl on long studs away from gear box ,just remove bearing plate and pull gear out ,there are 2 input gears used ftc5089 has 26 teeth and ftc5087 28 teeth you can either reuse old bearings if in good condition or fit new 2 x frc5564 but use timken pattern ones are ****,bearing plate contains a shim behind rear bearing race but should be okay with timken bearings and shouldnt need changing,check by rotating gear once installed