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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6772
England 2004 Defender 110 Td5 CSW Bonatti Grey
Urgent worried transfer box question
I bought a used td5 disco transfer box to go on my 110 and its going in to the garage tomorrow to have it put on along with a new DMF and clutch. To speed the job along I said I'd strip out the interior and tunnel but I've just looked over the transfer box that's already in the 110 and there's wires going to a plug inbetween the handbrake drum and the main bit of the transfer box, mounted into the rear output shaft casing of the box. On my disco transfer box this is a blank bit of the casting, so my questions are does anyone know what this plug is and if it's ok to leave it out?

Any answers great fully received as I'm really in a time crunch now Big Cry

Cheers
Ray
Post #366436 22nd Oct 2014 1:49pm
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rallysteve



Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2238
United Kingdom 2002 Defender 110 Td5 DCPU Keswick Green
Sounds like the speed transducer. Has the new transfer box got a centre diff lock as I thought only the models with traction control had no speedo drive as it came from the abs reluctor ring signals. 02' 110 TD5 Double Cab Rebuild Thread
Post #366437 22nd Oct 2014 1:51pm
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Martin
Site Admin


Member Since: 02 Apr 2007
Location: Hook Norton
Posts: 6638
United Kingdom 2015 Defender 90 Puma 2.2 XS CSW Montalcino Red
It sounds like you are describing the speedo sensor, a hole for which is not fitted to the Disco2 box.

It's just one of the things I also learned about the so-called "straight swap" between the Def and D2 box Rolling Eyes

You will need to swap the housing and brake drum etc onto the D2 box.  1988 90 Td5 NAS soft top
2015 D90 XS SW
Post #366438 22nd Oct 2014 1:53pm
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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6772
England 2004 Defender 110 Td5 CSW Bonatti Grey
Big Cry that s pain if I have to swap that bit of the housing as I just put a new output shaft seal in Evil or Very Mad it does have diff lock but has none of the rods so these will be swapped over too. It seams like you say martin that's it's not quite a straight swap Big Cry
Post #366440 22nd Oct 2014 1:59pm
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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6772
England 2004 Defender 110 Td5 CSW Bonatti Grey
Can I ask martin, is it just a straight unbolt and swap over or is it a more involved job?

Cheers
Ray
Post #366452 22nd Oct 2014 3:28pm
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Fatboy Slim



Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006
Wales 
Undo the housing complete with the output shaft and swap the lot over. Easy peasy. You'll also need to swap the front flange as the D2 one is different. Easy peasy again.
Post #366473 22nd Oct 2014 5:32pm
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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6772
England 2004 Defender 110 Td5 CSW Bonatti Grey
Shocked won't all the gubbins fall out if I take the output shaft out too? I didn't think there would be this many differences on a disco TD5 box.
Post #366503 22nd Oct 2014 7:08pm
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taazzukcb



Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663
United Kingdom 2004 Defender 110 Td5 DCPU Stornoway Grey
On a side note, keep me posted on the DMF!

I have a clutch and DMF on the way so will check mine out next week. Also tempted to fit a D2 box to! Sounds like it's just easier to swap the internals over!
Post #366525 22nd Oct 2014 8:36pm
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Fatboy Slim



Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006
Wales 
Nope, nothing falls out. Done many of them, use a good quality sealant on the mating faces. 20 mins work tops.
Post #366535 22nd Oct 2014 9:16pm
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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6772
England 2004 Defender 110 Td5 CSW Bonatti Grey
Thumbs Up cheers for that fatboy slim. I've just stripped it, so the garage can swap all the bits over while it's all out and hopefully the transfer box is a good one Whistle
Taazz, I'll keep you posted. Hoping to get it back Friday.

Cheers
Ray
Post #366560 22nd Oct 2014 10:45pm
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skoller



Member Since: 27 Oct 2011
Location: australia
Posts: 7
Speaking about the speed transducer, does anyone know if its sealed with an o ring or gasket to the transfer box. Mine is weeping a bit of oil and would like to know a little bit about it before I try to fix it. I think I can get to it by removing the plate between the seats.
Post #366564 23rd Oct 2014 12:46am
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taazzukcb



Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663
United Kingdom 2004 Defender 110 Td5 DCPU Stornoway Grey
Yep, see below:




Click image to enlarge
Post #366584 23rd Oct 2014 7:36am
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skoller



Member Since: 27 Oct 2011
Location: australia
Posts: 7
Looks good. Thank you
Post #366603 23rd Oct 2014 9:20am
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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6772
England 2004 Defender 110 Td5 CSW Bonatti Grey
All done and fitted and seems good so far Thumbs Up

Thanks again for the help

Ray
Post #367177 25th Oct 2014 10:45pm
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