Transfer box swap defender

afternoon all

I want to change my 1.667 transfer box to a discovery 1.2 how much would it cost me?
Also how hard is it to do myself

Cheers
Rory

Easy enough to do
if you buy a recon it will be around £500

I changed mine from 1.66 to 1.4 (keeping with the na), dead easy to do. I went for engine crane thru the centre panel between seats. I've heard using threaded bar in the bolt holes aids alignment when bolting back onto the gearbox.

I paid £40 from a friend for a 1:2 off a disco from my TD51:4. Local LR mechanic wanted £200 for one off the used shelf. Job took me a few hours, worst part is the gear lever connections. You may need to swap a few parts around so make sure you do that first (handbrake). What engine do you have and how much power is it making? My TD5 is making about 160BHP and going to a 1:2 has seriously slowed it down on 33" tyres. 1:4 was good and I almost wish I'd stuck with it. I was still getting 80MPH without screaming the nuts off it.
Oh and make sure you stick a new seal on the input shaft hole (loads of sealant helps too), it's a box off job to replace (I know from experience)

Depends what condition you get the box in.
If you're going to be doing alot of towing I'd try one before you swap it it's brilliant for a mainly road driver but abit harsher for heavy load towing. I did it on my 300 tdi though and it drives a million times better.
Might want to get someone else to give you a hand too it can be awkward to line everything up on your own
Isn't terribly hard and there's plenty of step by step guides too
Might also be worth putting new prop shaft seals front and back of the box + flanges and changing/adjusting brake shoes if need
Also gives you chance to change bolts behind the prop flange which is awkward from underneath!
And don't forget to change the speedo gear too as the Disco one be too high I think. The one out old box should work if it isn't worn if is perfect chance for more swaps haha

Don't bother with a 1.2-1 transfer boxif you still have a 2.5 n/a diesel (presume it's 2.5 n/a if it's got a 1.6-1 box) it won't pull it.
On the other hand I have a 300tdi in my ex-army 110 and fitting a 1.2-1 transfer box transformed it.
I also tow a horse box with it and hill starts do need a few more revs, if you tow a big trailer every day then a 1.4-1 may be more sensible.
With the 1.2-1 box third gear is about where 5th was with the 1.6-box (ish). It is also worth noting that the military spec LT77 main gear-box has a slightly lower 1st gear than standard boxes.
I used a Discovery transfer box on mine and swapped the rear output housing from the 1.6-1 box as it was drilled and tapped for the 110 handbrake bracket. This also has the correct speedo drive for 750 tyres. I also swapped over the 110 handbrake back-plate as the Discovery hand brake is different.

Willbof said:

I paid £40 from a friend for a 1:2 off a disco from my TD51:4. Local LR mechanic wanted £200 for one off the used shelf. Job took me a few hours, worst part is the gear lever connections. You may need to swap a few parts around so make sure you do that first (handbrake). What engine do you have and how much power is it making? My TD5 is making about 160BHP and going to a 1:2 has seriously slowed it down on 33" tyres. 1:4 was good and I almost wish I'd stuck with it. I was still getting 80MPH without screaming the nuts off it.
Oh and make sure you stick a new seal on the input shaft hole (loads of sealant helps too), it's a box off job to replace (I know from experience)

Click to expand...

that's interesting because my td5 is on a 1.2 and 33's but I feel it's flat and towing is a chore.
I've got a few leaks and play on the rear output shaft so I'm thinking of swapping for a 1.4 rather than stripping it down

gazman said:

that's interesting because my td5 is on a 1.2 and 33's but I feel it's flat and towing is a chore.
I've got a few leaks and play on the rear output shaft so I'm thinking of swapping for a 1.4 rather than stripping it down

Click to expand...

1:4 for the win. If I did much towing I'd be switching back immediately!

Willbof said:

1:4 for the win. If I did much towing I'd be switching back immediately!

Click to expand...

I don't do loads but a few times a year.
The majority of my driving is motorway but the 33" tyres are about the same as a 1.2 box on the tyres it was on

I wouldn't bother with the 1.2 if I were you. My 300 tdi is fitted with one of them and thanks to it, i cannot fit tyres larger than 31". I know that swapping is an easy and relatively inexpensive task but I plan on changing the vehicle within the next 2 years so I won't bother.

Rory 110 said:

afternoon all

I want to change my 1.667 transfer box to a discovery 1.2 how much would it cost me?
Also how hard is it to do myself

Cheers
Rory

Click to expand...

Depends, there are heaps of Disco transfer boxes about as many of the donor vehicles are off for scrap. I paid £40 for mine about 6 years ago, came from a Disco the guy had broken for the engine and axles. He told me it was in excellent condition and he was not kidding.

I did it on a gravel car bay in an afternoon with help from my brother for the heavy lifting bits, but I am heavily experienced and have a full tool chest...

gazman said:

that's interesting because my td5 is on a 1.2 and 33's but I feel it's flat and towing is a chore.
I've got a few leaks and play on the rear output shaft so I'm thinking of swapping for a 1.4 rather than stripping it down

Click to expand...

Is your TD5 making more than standard power? If not then yes a 1.2 would definitely feel flat as it only makes about 120bhp from the factory! The 300tdi is about 110bhp. Like I said I'm making about 160 in mine and even that feels a bit sluggish compared to when I had the 1.4 fitted.

mine is roughly std.
It was fine on normal wheels, but the 33" tyres slowed it and then the roof rack etc really took the wind out of its sails

So what tyres would I need to gear it up abit?

I have 7j steels to go on just need tyres
Do I need wheel spacers? Or anything else I'm new to Landy scene
All help would be much appreciated