Disco 2 Replacing transfer box and handbrake gaiters - step by step

I know this has probably been covered before, but in case someone comes looking for a how-to, I just did mine, which is an automatic. Replaced both transfer box and handbrake gaiters.

Sadly, my mobile phone is knackered so I didn't take any photos.

Tools and parts needed:

• Contact adhesive (got mine from Wilko for £1.95, but any one will do)
• Wooden clothes pegs (they won´t leave a mark on the leather)
• Phillips screwdriver to remove electric window panel next to handbrake
• Set of gaiters from eBay (mine were £11.99, real leather)

Transfer box (same instructions for manual gear box gaiter):

1. Transfer box gaiter simply unclips by squeezing the sides of the square base and pulling. It should come free fairly easily. Pull it up near the knob.
2. Unscrew the knob, rotating the gaiter at the same time.
3. Once out, turn the gaiter inside out so you can access the rubber band that holds the knob in place. Remove and save for later.
4. The gaiter is glued to the base. You need to remove it without breaking the base, so be careful. It should come off easily by hand.
5. Note the word "FRONT" on the gaiter plastic base. Don´t forget where this is, as it will be covered when you glue the new gaiter on.
6. Get your new gaiter, noting that the stitching should be oriented to the sides of the base, apply adhesive to the base and wrap the edges of the gaiter around the plastic base. Apply 3 or 4 pegs to each side and to the corners. You can be pretty rough when pulling the edges of the leather to align properly, it won´t rip easily.
7. Let it dry for an hour. Remove pegs.
8. Pull the gaiter inside out, place the rubber band over the smaller opening on the gaiter, place the knob through the opening (facing the "FRONT") and slide the rubber band over the knob. Turn inside out again.
9. Screw the knob in place as you rotate both the knob and the gaiter at the same time so it doesn´t rip or twists too much.
10. Click the gaiter base in place - Done!

Handbrake gaiter

1. Unclip the electric windows plastic cover next to the handbrake. You don´t need any tools for this, it should come away easily.
2. Remove 4 screws from panel underneath. Lift panel carefully so not to pull the connections behind it. You don´t need to disconnect any of them, simply pull it carefully to one side.
3. Unclip handbrake gaiter base. It´s a thin, square metal wire (almost like a coat hanger), pressure fitted on the top and bottom.
4. Pull the gaiter inside out over the handbrake until it exposes the rubber band.
5. Remove rubber band, save it for later, and pull the gaiter over the handbrake grip. It may be a bit tight, but just pull it, it will come off - saves having to remove the grip, which is glued in place.
6. Remove the old gaiter, which is also glued to the metal base, noting the orientation of the black plastic roller on the metal base- it should be on the bottom. The gaiter should come away easily by hand
7. Glue the new gaiter in place, adjusting it so the corner openings of the metal base are visible. Use the clothes pegs to hold it in place while it dries (1 hour should be enough).
8. Turn gaiter inside out, slide rubber band over the gaiter.
9. Align small opening on the gaiter with the handbrake grip and slide it over until the edges of the gaiter are over the groove on the back of the grip. It should be an easy fit.
10. Make sure the gaiter is in the correct orientation, with the straight edge on top and the slightly curved edge underneath.
11. Slide the rubber band over to the groove, so it pinches the edges of the gaiter in place.
12. Turn the gaiter inside out over the handbrake. You need to force it a bit.
13. Pressure fit the metal base in place, both top and bottom.
14. Return the electric windows panel to its place, put the 4 screws back in and clip the cover panel back on - Done!

Took me about an hour and 15 minutes to do the whole thing, including 1 hour drying time.

Hope it was useful.

Good write up. Mine has the posh veneer panel so is much harder to get the switch panel off but when I did the handbrake gaiter several years ago it was possible just by springing the wire clip out.