whats the best gear box and transfer

Hi Guys,

I'm looking for some tips and wondering if anyone knows. I'm not terrably impressed with the lt77 transmission in my 200tdi.
I heard the later 300tdi trany is better.
I see people advertising berg worner gear boxes are these any good?

What is the best manual transmission, and transfer for a disco (for general use on and off road).

Also I need to replace my back axle, there is a disco 2 one at the breakers, will this fit a disco one. Also out of interest sake can you fit a 300tdi motor in a 200tdi, or does the later model have an ecu?

Cheers Jim

R380 is better than lt77, I just reconned my lt77 and should have fitted r380 instead.

Lt230 transfer case is fine, leave as is. Chain drive Borg warner? Hmmm, no thanks.

Disco2 back axle completely different, get a 200tdi back axle. Even 300tdi slightly different, will fit no probs, but must be complete, different diff, shafts, hub etc.

300tdi has stronger drivetrain so a good upgrade for an offroader. What's up with your axle?

Also why fit 300tdi, basically same engine, bit more power, bit more complex innit?

Thanks for the tips mr noisy. I think I'll look for a 300tdi gearbox then, sound likle it makes sense.

Its ok for the 200tdi transfer to fit the 300tdi gearbox?

I probably will need to shift my back axle not because of mechanics but because of rust! Again think I'll look for a 300tdi complete unit then.

What about the salisbury axle, are they something special?

Was only asking about the motor as was thinking maybe I should be a complete parts car. I am very happy with the simplicity of the 200tdi, though its not the most powerfull 115hp engine I've ever used...but at least its cheap on fuel and easy to work on!

200 and 300 have same transfer.

maybe slightly different internally, because of age of manufacture, but they are identical basically.

worst case scenario you would have to change the transfer box input gear to fit r380, thats a 20 minute job to change and costs 40 quid new. tis a good idea to change it whilst the box is off anyway, cos they wear a lot.

yeah back axle wise, its the same axle but the internals are uprated, so worthwhile doing. its will fit directly, but you just got to remember to order 300 shape spares for your back axle, 200 shape for the front!

my back axle was very rusty i thought, but i took the diff out and the diff pan was fine inside, still quite good thickness too. worth checking before splashing out.

i had a big hole in the rear damper mount and a spring mount had collapsed, but i just replaced them and it cost about a tenner, took a few hours to grind of and weld on new items.

not sure about salisbury, think theyre totally different though. 110 territory!!

as for the motor, in my eyes the 200 shape is the beter car due to simplicity in electrics. ok the 300 had better drivetrain, but the engine is similar and its a much more complicated car.

look at wiring diagrams in haynes manual:

200 = easy peasy. yes please, easy to fix.
300 = damn complex. no thanks, rather not bother.

i would do some tuning to your 200tdi and it'll be a better performer.

cheers, sam

If you're putting a 300 engine into a 200 you'll need to alter the engine mounts me thinks.

Thanks for tips mr noisy, puts me in good stead. I will definately stick with 200tdi motors. To be honest theirs nothing wrong with my motor just preparing for when there is. Its an 18 year old car after all...

Definately gonna look for a 300tdi gearbox, and will change the input gear on the transfer as I get a wicked amount of back lash, and I suspect this could be the cause (all though others say its farly typical something must be casuing it in my opinion)

Back axle is rusty but works ok, spring mounts have corroded through other mounts ok. I will be changing springs so have ordered new mounts. Will try this first but long term will probably uprate to 300. Why is the 300 stronger is that to do with the 10 spline/24 spline thing.

Thanks Jim

Hi mate

You will have backlash in your gearbox, your transfer and your diffs.

R380 will cure a lot, input gear some more, and a 300 diff hopefully some more.

Yeah the 300 has 24 spline hubs, shafts and diff centres.

Splines are stronger, shafts are thicker.

Cheers

There's a rear 300tdi axle on eBay for 60quid

Hey Mr Noisy, was just wondering as you did a simaler job to what I have to do on your axle (change spring mount) what type of welder you used. I'm pretty new to welding I have a small mig that I have quickly (very quickly) out grown and am thinking of getting somethingg stronger with gas thats strong enough to at least weld the axle. Cheers Jim

Hi Jim

I haven't learnt to weld myself, because I have a good mate who's happy to help out!

He uses a siegen MIG150, uses .8mm wire and Argoshield gas.

Seems to do the job ok, but wasn't really hot enough to do the axle tbh.

Has never shifted, but I doubt the penetration was as good as it should have been.

"we" have done front wings, sills, and general body repair and it has been spot on though.

Cheers.