transfer box replacement

bart2181 · Oct 2, 2009

i own a 1998 3.9 v8 disco with autobox,due to a clunk noise im needing a transfer box exchange.now does anyone know what transfer box is suitable and how difficult is it to change for the average home mechanic.any help much appreciated.

pete23 · Oct 2, 2009

i think its a standard box the same as a 90, its very easy to do, but you could do with a extra pair of hands to get it off and back on.
not sure but there may be a link on here of "how to do it"

byway-basher · Oct 2, 2009

Defender transfer boxes have different ratios, Disco and RRC are the same ratios.

It can be done on the driveway, but its heavy, awkward and some of the bolts can be tricky to reach. It can be quicker and easier to take the gearbox out with the transfer box, then split them.

Sean · Oct 2, 2009

byway-basher said:
It can be quicker and easier to take the gearbox out with the transfer box, then split them.

ermm no it isnt .......

get some long (200mm ish) M10 bolts - cut the heads off and put a slot in the end (for a screwdriver) - undo the tranny box bolts and replace them one by one with the long bolts - when all are replaced slide the tranny box away from the GB, once the shaft has cleared lower the tranny onto yer skateboard

don't forget to have plenty for breakfast before you start

bart2181 · Oct 2, 2009

great idea sean.i,ll be lying on my back when i pull the transfer box away what sort of weight can i expect when it drops?i,ve just changed the rear diff,whats the comparison in weight.cheers

The Mad Hat Man · Oct 2, 2009

Use a trolley jack to support it.

thebiglad · Oct 3, 2009

I've just done a clutch on a Disco TDi 300 so had to split the gear/trans box assembly from the engine and the weight was enormous, I would guess at 300kgs.

I had another pair of strong hands to help me plus we had a good trolley jack underneath.

I would gues the trans box at 150kgs.

hughesy · Oct 3, 2009

thebiglad said:
I've just done a clutch on a Disco TDi 300 so had to split the gear/trans box assembly from the engine and the weight was enormous, I would guess at 300kgs.

I had another pair of strong hands to help me plus we had a good trolley jack underneath.

I would gues the trans box at 150kgs.

I think you're a bit wide of the mark there. A transfer box on it's own weighs about 60kg. Easy enough to handle once removed but bloody awkward to maneouvre in a tight space like under the vehicle. A gearbox and transfer box combined is about at the limit of what one person can lift on their own, probably well over 100kg.

thebiglad · Oct 3, 2009

hughesy said:
I think you're a bit wide of the mark there. A transfer box on it's own weighs about 60kg. Easy enough to handle once removed but bloody awkward to maneouvre in a tight space like under the vehicle. A gearbox and transfer box combined is about at the limit of what one person can lift on their own, probably well over 100kg.

You may well be right, all I know is that the combined assembly was LOADS heavier than the log burner stove that I just installed and that weighed in at 180kgs

What I do know is, they are bloôdy heavy enough when you are trying to man-handle them underneath a Disco

transfer box replacement

bart2181

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