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MC84

Member Since: 22 May 2016
Location: Near Bristol
Posts: 360

LT230 electric switches question

I have bought a LT230 transfer box to fit to my 2001 TD5 90 truck to convert it from 1.4 to 1.2 ratio. The "new" one came out of a Disco automatic I understand. It has the diff lock and hi/low levers and one switch which actuates when I select diff lock. Reading on the forum I have heard of another switch that tells the ECU what range (Hi/low) you are in and alters the throttle response. Am I correct and I'm missing a switch? Mike

Hard Top 90 TD5 2001
Ford 100e 1959
www.youtube.com/mikemakesit

29th Sep 2017 10:16pm

Martin
Site Admin

Member Since: 02 Apr 2007
Location: Hook Norton
Posts: 6611

2015 Defender 90 Puma 2.2 XS CSW Montalcino Red

Sounds like it. I assume your 1.2:1 box is out of a Series 1 (Tdi era) Disco not S2?

1988 90 Td5 NAS soft top

2015 D90 XS SW

30th Sep 2017 10:14am

MC84

Member Since: 22 May 2016
Location: Near Bristol
Posts: 360

Hi Martin, not too sure where it came from but could a switch be fitted? Where does the switch live normally? Mike

Hard Top 90 TD5 2001
Ford 100e 1959
www.youtube.com/mikemakesit

30th Sep 2017 6:03pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

Click image to enlarge

red line to the low and high switch orange line to the dif lock switch

30th Sep 2017 7:27pm

MC84

Member Since: 22 May 2016
Location: Near Bristol
Posts: 360

Many thanks dorestsmith. What do people do with regards the missing switch? Is it possible to fit one to the casing? Mike

Hard Top 90 TD5 2001
Ford 100e 1959
www.youtube.com/mikemakesit

30th Sep 2017 8:05pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

if you are missing tapped hole to fit switch

30th Sep 2017 8:07pm

MC84

Member Since: 22 May 2016
Location: Near Bristol
Posts: 360

I'm missing the Hi/low switch. And hole! Mike

Hard Top 90 TD5 2001
Ford 100e 1959
www.youtube.com/mikemakesit

30th Sep 2017 8:31pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

do you have pic of your disco Lt230 box

30th Sep 2017 8:50pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17450

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

It probably won't matter much not having it, you'll just have the standard throttle all the time. It should still drive ok in low range, just be lighter on the pedal.

30th Sep 2017 9:37pm

MC84

Member Since: 22 May 2016
Location: Near Bristol
Posts: 360

I'll upload a pic tomorrow, at work at the mo! Mike

Hard Top 90 TD5 2001
Ford 100e 1959
www.youtube.com/mikemakesit

1st Oct 2017 12:11am

MC84

Member Since: 22 May 2016
Location: Near Bristol
Posts: 360

Picture of my transfer box. I've circled the place I may be able to drill for the new switch.

Click image to enlarge Mike

Hard Top 90 TD5 2001
Ford 100e 1959
www.youtube.com/mikemakesit

1st Oct 2017 5:43pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

if you remover six bolts top your box and check in side for High/Low selector finger that moves the switch and Fork-high/low selector
also metal serf from drill and tapping will need clean out good luck

Last edited by dorsetsmith on 1st Oct 2017 6:15pm. Edited 1 time in total

1st Oct 2017 5:58pm

4RF RDS

Member Since: 19 Jul 2015
Location: Ottawa
Posts: 942

2000 Defender 110 Td5 XS CSW Epsom Green

Or switch the gear set into your old transfer case... 2010 Range Rover MkIII Autobiography Super Charged (Idris)
2003 Range Rover Mk III (Desmond FitzWilliam)
2000 Defender 110 CSW TD5 (CTX)
1992 Range Rover Classic (Lizzy)
1972 Series III 300 Tdi (Stanwood)
1967 MGB GT

Every normal man must be tempted at times to spit on his hands, hoist the black flag, and begin to slit throats.
H. L. Mencken (1880 - 1956)

1st Oct 2017 6:14pm

achuakh

Member Since: 12 Apr 2012
Location: Singapore
Posts: 158

i'm believing that box came out of a disco Tdi300. so yes, you are right, you need to port over the hilow detect switch housing.

when you put the boxes side by side, you will see what is missing and what you need to swap over. it's nothing complicated. i did that on mine. From the land of the most expensive land rover defenders on planet earth. At �125k for a XS 110 csw and you get to own it only for 10yrs! Please find me a good reason to stay on this island.

2nd Oct 2017 4:11pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17450

If you're swapping the front output housing from one box to another, be mindful of the fact the front diff bearing is in the housing you're swapping. You don't really want to mix the bearing races, and you may need to reshim the front bearing to set the bearing preload due to machining differences between the housings.

2nd Oct 2017 7:35pm

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