Disco 2 Transfer Box Reliability

Evening All

How reliable is the transfer box on the TD5 (2004)? I've already replaced the gearbox with an Ashcrofts refurb unit, but I'm just wondering if I'm going to have to change the transfer box in the future. Lets for arguments sake assume it's not been abused and had an oil change every 6k miles, which is the case since I've owned it (5 years and with 135k miles on the engine)

I'm not experiencing any issues with it now, I'm just planning ahead

185k on mine.
Silent as a church mouse
Auto box is original too

Servicing FTW

Edited Original question

In my experience, auto box and T box are bulletproof, although I’ve never had to move the T box from its high ratio, and both connect to an 8 cylinder engine and I don’t hang around.

The LT230 is very robust and will outlive the chassis for sure However, early versions suffered from lack of lubrication on the input gears, causing damage to the splines. I would expect the 2004 not to be one of these but you never know. Here's a link : https://www.ashcroft-transmissions.co.uk/diy-rebuild-kits/lt230-rebuild-kits/input-gear.html

After 16 years I would expect your O-ring seals on the intermediate shaft to have hardened and started to flatten out which will start as a weep and turn into an incessant leak and drip as time goes by.

Output shaft seals are also prone to ageing and going hard which in turn turns into a leak and as soon as the output bearings get a little play it gets really messy.

If you are at all suspecting your box needs attention then post up in the freelander forum for all the back door action a man can ask for

Failing that just get on the horn to Ashcrofts for a newly rebuilt one and you'll have peace of mind until you die.

NPG said:

The LT230 is very robust and will outlive the chassis for sure However, early versions suffered from lack of lubrication on the input gears, causing damage to the splines. I would expect the 2004 not to be one of these but you never know.

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+1 IME - two weaknesses in the LT230 - one is a design oversight - I.E. this one As above, yours is young enough that unless some muppett has put an old one on it won't be affected

dieseldog69 said:

After 16 years I would expect your O-ring seals on the intermediate shaft to have hardened and started to flatten out which will start as a weep and turn into an incessant leak and drip as time goes by.

Output shaft seals are also prone to ageing and going hard which in turn turns into a leak and as soon as the output bearings get a little play it gets really messy.

Click to expand...

Also +1 - this is the other issue.... the seals do fail / wear out = very rude of them Not a bad DIY prospect though

Of all the things on a D2, the LT230 is about the last thing I'd be worried about, especially if, as you say, its had regular oil changes. There's one here with nearly 200 K on it, and it is also as quiet as a mouse, with very little play, and, weirdly, no leaks

The previous owner of my defender replaced the transfer box at 200k. It failed because it had a slight leak and oil level went low

Yeah the input gear issue would be gone by 04. My old D1 had wear there from low oil due to a leak though. So like everything on an LR, if its been looked after it will be good.
Interestingly, you can bodge a worn input gear with nails or thin strips of steel. I don’t recommend it, but it saves that clunk which is very annoying