transfer box

hi i have a 1991 200tdi 90 with lt230 transfer box the transfer box leaks oil out of the front flange which i understand is an easy fix. However there is also a huge amount of play in the transmission which i believe is down to the worn transfer box so i am thinking of replacing the box. i have kicking about a transfer box from an old range rover classic which is good because i drove the car before it fell apart. however i need to know if the rangie box has a higher gearing in high ratio because i already have range rover axles and don't want to gear up my car any more due to towing needs. thanks Ed

rrc will have 1.222 transfer box ratio,check input gear mainshaft wear by removing pto cover on rear ot transfer box first ,if splines arew worn new input gear for t/box is easy new mainshaft for gearbox needs full rebuild ,dont replace one wont last much longer,transfer box other wear is down to lack of oil changes and level defender ans disco and rrc have the same diffs apart from 110 rear salisbury

thanks is the defender transfer box also 1.222? if my mainshaft is worn is a recon gearbox from somewhere like ashcrofts advisable or are there any tricks to fix old one?
Ed

steady93 said:

thanks is the defender transfer box also 1.222? if my mainshaft is worn is a recon gearbox from somewhere like ashcrofts advisable or are there any tricks to fix old one?
Ed

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no shouldnt be if its the factory fit 90.it should be 1.4 i think.

rrc transfer will gear it up but you have low box.depends on how many road miles you do.1.222 will suit for running about empty.It may not suit towing.depends again what you do.

Wack in the rrc tbox and try it while rebuilding the original.

check input gear first then diffs props etc before you buy ,ive supplied a lot of garages with a gear box ,then transfer box then diff and you wonder if was all 3

right i have just taken my front prop off and the clunk is still there, i took the centre seat out and the panel under it so i could see the handbrake drum when i set of the clunk happend before the rear prop started to move which presumably means its from inside the transfer box when i laid underneath and wiggled things it sounded like the gear box ! does this suggest it is the input gear and mainshaft that are worn ? i took the pto cover off but couldnt really tell much from it not knowing what was what

pull the gear out and have a look it will be obvious then

worn clutch fork and input shaft spline is my bet,imminent clutch failer i reckon.

took the cover off and pulled it out and your right the shaft from the back of the gearbox is worn badly as well as the bit inside the transfer box, cant really afford a recon box atm so does anyone see any problems with welding the two together?

really needs new input gear and mainshaft which is gearbox £400 plus fitting ,ive seen a few welded ,

steady93 said:

took the cover off and pulled it out and your right the shaft from the back of the gearbox is worn badly as well as the bit inside the transfer box, cant really afford a recon box atm so does anyone see any problems with welding the two together?

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pretty sure if you get a new crossed drilled input gear for the transfer box, they are desigened with much longer internal splines. Therefore it will make use of a nice bit of unwarn spline on the gearbox output shaft, which will solve your problem.

that dont work on lt77 as all of spline will be worn,its welding or replace

suffix c or later for cross drilled gear

jamesmartin said:

that dont work on lt77 as all of spline will be worn,its welding or replace

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ok, if you say so.

worked a treat on my lt77 though....

you must have had strange wear then lt77 has same sized spline as input gear r380 has the longer splines

jamesmartin said:

you must have had strange wear then lt77 has same sized spline as input gear r380 has the longer splines

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Yeah I guess so. The input gear that came off defo only had 2 thirds length of splines compared to the crossed drilled one that went on. The lt77 output shaft was only (i say only) 2 thirds Knacked. How odd.

yes it is odd ,cross drilled gear has longer splines as r380 shaft has splines from end to near seal lt77 has only short splines ,yours may have been like that but generally there all gone, ive built alot more than a 1000 ,most for spline wear ,and input gear splines are the same size as shaft splines on an lt77

jamesmartin said:

yes it is odd ,cross drilled gear has longer splines as r380 shaft has splines from end to near seal lt77 has only short splines ,yours may have been like that but generally there all gone, ive built alot more than a 1000 ,most for spline wear ,and input gear splines are the same size as shaft splines on an lt77

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cool...best ignore my comments then.

1000+ to 1 is a bit tricky to defend.