Transfer box rebuild with Disco Gears !

Jason2 · Feb 22, 2014

Hi

Not a debate as I already have another 200tdi 110 with a Disco transfer box and I love it

I would like the same gearing on my TD5 110 (has a stage 1 tune) but transport on an exchange unit to and from the UK would cost a fourtune.

I have an old noisy leaking Lt230 off my Def 200tdi and a LT230 in bit's off a 200tdi Discovery . I know that the gears from the Disco box will go in, question is how easy is it to do it right, i.e full recon with new bearings seals etc and will a LT 230 off a 200tdi go on a TD5.

Long Job? Pain in the arse to do ? & is it worth it as the price of parts rack up quick !!

Thanks in advance

Jason

ferretboy · Feb 22, 2014

It will all fit ! You will need pullers to get bearings off shafts and a few tubes ov varying diameter to refit bearings and seals ! Steam the box off well first !

jamesmartin · Feb 22, 2014

Jason2 said:
Hi

Not a debate as I already have another 200tdi 110 with a Disco transfer box and I love it

I would like the same gearing on my TD5 110 (has a stage 1 tune) but transport on an exchange unit to and from the UK would cost a fourtune.

I have an old noisy leaking Lt230 off my Def 200tdi and a LT230 in bit's off a 200tdi Discovery . I know that the gears from the Disco box will go in, question is how easy is it to do it right, i.e full recon with new bearings seals etc and will a LT 230 off a 200tdi go on a TD5.

Long Job? Pain in the arse to do ? & is it worth it as the price of parts rack up quick !!

Thanks in advance

Jason

you need to check different aged boxes use different gears in that teeth count vary and there are 2 types of dog teeth on high and low gears , but if you google stc1130 x2,frc5564 x2 ,stc3185 x2,606747 x1 ,frc7871 x1 you will know price of bearings needed

Jason2 · Feb 22, 2014

Thanks a lot for your replies.

My Disco LT230 is N° 28D242614E and my Def box is N° 22D187763D .

jamesmartin · Feb 22, 2014

Jason2 said:
Thanks a lot for your replies.

My Disco LT230 is N° 28D242614E and my Def box is N° 22D187763D .

id fit td5 front housing on the disco box ,whilst rebuilding disco box

Jason2 · Feb 22, 2014

jamesmartin said:
id fit td5 front housing on the disco box ,whilst rebuilding disco box

Cheers James but why & where would I get one of them from. My thoughts were to rebuild the Def box not that it matters like ! I don't want to touch my current td5 TF box as the vehicle is used daily and won't have time to take it off and muck about !

Besides it's going in a glass case on the mantle piece as it's the only one that I've ever had that dunt leak

jamesmartin · Feb 22, 2014

just fit complete disco box then and rewire hi/lo switch to a switch in the cab

Jason2 · Feb 22, 2014

Not over keen on that Idea as the Disco box was in bit's when I got it and don't even kow if it's all there. My thought was to take the gears out of the Disco box and put them in the Def box but can see where you are coming from by leaving them in the Disco box to avoid mating foreign gears-

jamesmartin · Feb 22, 2014

Jason2 said:
Not over keen on that Idea as the Disco box was in bit's when I got it and don't even kow if it's all there. My thought was to take the gears out of the Disco box and put them in the Def box but can see where you are coming from by leaving them in the Disco box to avoid mating foreign gears-

e and a d depending on serial number wont intermix gear wise, though you could swap all

Jason2 · Feb 23, 2014

jamesmartin said:
e and a d depending on serial number wont intermix gear wise, though you could swap all

Cheers matey

That's saved me from an expensive disaster

Jason2 · Mar 5, 2014

I have decided to rebuild my Disco Lt230, stripped it down and it does'nt look to bad

Bearings, cross drilled imput gear ordered, already had a geasket/seal set. Was just wondering if the speedo electronic gizmo off my TD5 and any other electrickery is just a straight swap over ???

Cheers !

jamesmartin · Mar 5, 2014

speedo drive will just pull out and swap .dont use gaskets on t/boxes 300tdi on which use sealant instead (rtv silicone)it will make shimming input and center diff up correctly,hi/low senors on front of td5 box wont fit on a 300tdi or previous box as no provision in front housing

Jason2 · Mar 5, 2014

Thanks James

Why not use gaskets ?? Old box has them ??

jamesmartin · Mar 5, 2014

Jason2 said:
Thanks James

Why not use gaskets ?? Old box has them ??

if iold box has them then it must be 200 tdi and previous ,and then you need to use gaskets for the same reason of altering the shimming further than shims lr provide to cater for

Jason2 · Mar 5, 2014

Thanks once again

Yes it's a 200tdi box .

Going to change all bearings, seals, output flanges ! anything else ?

Also was half tempted to get one of them bigger sump cooler jobs but there not cheap

anybody got any feedback on them ?

Jason2 · Mar 5, 2014

Them's things I'm on about ?

jamesmartin · Mar 5, 2014

Jason2 said:
Them's things I'm on about ?

diff washers and pins are worth doing when its apart one of the most failing parts ,i wouldnt bother with the sump

Jason2 · Mar 31, 2014

James !!!

What do I do wiv the electric plug connection on the TD5 Transfer box that I've not got on the 200tdi Transfer box.

Just leave it dangling

All sorted but I've buggered me back up so will have to wait till that's sorted until I can put it on !!

Cheers matey

jamesmartin · Mar 31, 2014

connect the 2 wires to a switch in the cab, if we are talking about the high/low switch wires

Jason2 · Mar 31, 2014

jamesmartin said:
connect the 2 wires to a switch in the cab, if we are talking about the high/low switch wires

Cheers james them's the ones.

I take it them's the ones that tell the ECU that it's in low range and the the gaz peddle becomes less sensitive ? Yeh ?

Transfer box rebuild with Disco Gears !

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