Transfer Box Fitting

Any tips on fitting a transfer box please?

I've been on with it for a couple of hours but can't get it to mate to to the gearbox.

All bolt holes etc are perfectly inline. It feels as if it's sticking on the gearbox output to tbox input. It's about 1.5" away from engaging.

This is a disco box fitting to a defender.

Have you got the back cover (power take-off) removed?

Yes, I've removed the back cover, and the oil plate (with top on it). I've not managed to remove the input gears.

Apologies - I was headed towards bed and away with the Series fairies...

You shouldn't need the cover off, or the input gear out.

Which gearbox and which transfer box are you using?

No worries, I was also going to bed. It's an 77 gearbox and a 230 tb.

You may well need to rotate the gears to get the splines to engage as you push the box's together.

Yeah, I've been rotating the tb flange with the diff lock on.

Do some tb's have input gears with different numbers of splines on them?

Transfer box needs to be in gear as well,with back plate off you will see input gear turn and when splines line up,Early transfer box's do have a different gear.

sounds like suffix b box with oiler mod, are the splines on output rough?

It must be in gear because if I turn one flange, the other rotates. Main gearbox is not in gear. I'll have another go this morning.

fanatic said:

sounds like suffix b box with oiler mod, are the splines on output rough?

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It has the oiler plate. I've not seen the output splines.

sp00k said:

It has the oiler plate. I've not seen the output splines.

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surely if you removed it from 5 speed box- you saw them as they slide into input gear on transfer box

Sorry, I thought you meant on the tb. The splines on the gearbox aren't rough.

Right, the bugger went in, thanks for the tips everyone.

Bit of twiddling and it slid right on to make a fool out of me, Nothing new there. Don't know why it would not go yesterday, but today is a new day.

I was going to refit the PTO cover and went to put the oil plate back in. For those that know about these things, the back of the oil plate has an indent in it which pushes into the input gear. It looks like the output shaft is preventing this from going in.

Do these oil plates have different sizes ends for different shafts or can I drift the output shaft in. Looks like it would need to go in about 10mm.

Just read this: http://www.landyzone.co.uk/lz/f67/h...ur-spline-wear-lt230-transfer-box-226597.html So, it sounds like I need to get my drill out but it would be good to hear from someone with experience of this. Thnaks.