transfer box

Ian Maycock · Mar 4, 2016

Hi all, I know this has proberbly been asked before but I'm just off to work so haven't got a lot of time to search through lots of threads sorry. The stepsons transfer box has gone his mates given him one that he had as a spare, I know how to remove it but my question is can you remove the transfer box on a defender 90 300tdi from underneath instead of removing the seat box and all that and taking it through the cab ? as we want to start on it first thing tomorrow
thanks for any help Ian

Marmaduke · Mar 4, 2016

You can but you'll have countless years of detritus falling in your face, don't forget to drain the oil out before you start

zeaphod · Mar 4, 2016

Get some willing "volunteer" to go underneath with a wire brush first - while you make the first cup of tea. They will appreciate a set of goggles and a hat.

Brown · Mar 4, 2016

You can reach all the main fixing bolts from underneath. The difficult bit might be unhitching the linkage for the transfer box gearchange and centre difflock as I expect they'll be really hard to get at without taking the transmission tunnel off. Once it's undone, there's plenty of room to drag the old box out and new box in underneath. It's a heavy item and may be hard to lift into position exclusively from underneath. Maybe have two people working on it and find some suitable blocks or boxes to rest it on.

MeatCleaverX86 · Mar 4, 2016

yes you can do it all from underneath but the linkage and difflock switch are a fiddle and easier from above. You only need to remove the middle seat / access panel.

Thats how i done mine a few months back

Remove prop shafts, remove centre access panel in-between the seats, then hand brake drum (leave assembled and pass through to drivers seat) . disconnect speedo electrics and linkage. undo bolts to gear box and chassis mounts. then slide off they weigh a fair bit so you might want one person inside with a strop round it to help take the weight.

a helpfull hint remember which bolts go where as some will foul the gearing if put back in wrong place.

Ian Maycock · Mar 4, 2016

cheers all, the step sons doing the cleaning and unbolting bit I'm only joining in when its time to actually remove it

hahaha he broke it so he can get covered in the muck

Marmaduke · Mar 4, 2016

Personally I'd remove the seat bases, floor plates and transmission tunnel and lower it to the ground from above and then drag it out from underneath

frog hopper · Mar 4, 2016

For fitting the new box a really top tip somewhere on here (I used it and it works a treat) is to get hold of 3 long bolts about 4 inches long - cant remember what size but you'll be able to see when old bolts come out - cut the heads off and saw a screwdriver slot in the sawn end. Screw the long bolts into the gearbox and carefully slide the transfer box along these until it mates, take one out and fit the proper bolt, do the next etc. This helps enormously when trying to line everything up, saves the oil seal from potential damage and means your struggling to lift it for a far shorter time.

Marmaduke · Mar 4, 2016

frog hopper said:
For fitting the new box a really top tip somewhere on here (I used it and it works a treat) is to get hold of 3 long bolts about 4 inches long - cant remember what size but you'll be able to see when old bolts come out - cut the heads off and saw a screwdriver slot in the sawn end. Screw the long bolts into the gearbox and carefully slide the transfer box along these until it mates, take one out and fit the proper bolt, do the next etc. This helps enormously when trying to line everything up, saves the oil seal from potential damage and means your struggling to lift it for a far shorter time.

I'll try that when I swap mine as I'm planning on putting a Discovery one on mine in the near future, machine mart do 1mm cutting disks that should do the job nicely

Brown · Mar 4, 2016

Some of mine were studs that went into the gearbox casting, so they did the same job. A bit shorter though. The sense of relief when you get it on the studs is overwhelming.

Ian Maycock · Mar 5, 2016

you could use threaded bar, you can buy that in metre lengths and cut it to suit.

transfer box

Ian Maycock

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Marmaduke

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zeaphod

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Brown

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MeatCleaverX86

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Ian Maycock

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Marmaduke

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frog hopper

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Marmaduke

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Brown

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Ian Maycock

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