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MC84

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

Transfer box swap

Hi, I have a 2001 TD5 5 speed and I have a Disco auto transfer box I want to fit to it. A colleague has just said its not just a straight swap and that gears need to be changed in it due to the "new" box has come from and automatic. Is he wrong? Mike

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

1st Dec 2017 10:49pm

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4786

I believe the only thing to swap is the diff lock housing (if the new 'box doesn't have it) but might be wrong

2002 90 Td5 Station Wagon
1990 Vogue SE
Triumph Tiger Explorer 1200
Td5 90 Thread http://www.defender2.net/forum/topic50767.html
Tdi 110 Thread https://www.defender2.net/forum/topic69562.html
RRC Thread http://www.defender2.net/forum/topic54492.html
Instagram http://www.instagram.com/george_grafton

1st Dec 2017 11:46pm

barbel jim

Member Since: 12 Dec 2012
Location: Northants
Posts: 1423

and the speedo drive ring. Depending on the box, the front face could also be different, missing some electrical bits that governs the throttle response, and puts the diff light on, on the dash, You can swap, or leave off.

2nd Dec 2017 9:04am

MC84

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

Thanks for the reply guys.

What you say ties up with what I have read from the forum over the months. Clearly my colleague also needs to read it!!!!

Thanks again,

Mike Mike

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

3rd Dec 2017 4:11am

VVS210

Member Since: 12 Nov 2016
Location: Hampshire
Posts: 953

As others have said, you will need to swap the bits for the hi/Lo & diff lock from your existing box as the D2 set up is not the same. If you have a later D2 box then you will also need to swap out the casing & output shaft for the speedo drive as the D2 takes its speedo input from one of the front wheel sensors not the output shaft.

Having done this swap over the summer on my DCPU, I wouldn't do it again as I am now finding that pulling away with a trailer on anything other than a flat or downhill gradient requires higher revs & a bit of clutch slip. Once I have the season out of the way I will be looking for a standard Defender transfer box to replace it over the summer. If you're after a taller 5th gear for road work my advice would be to go for gear swap in the main box.

Just my thoughts based on experience.

3rd Dec 2017 10:47am

diesel_jim

Member Since: 13 Oct 2008
Location: hiding
Posts: 6093

I did just the ssme thing with my 110.... got a later D2 box which didn't have difflock or the rear speedo transducer hole.

I just stripped the bits off of my existing box and swapped them over.

The rear housing does hold part of the bearing race though... a few emails with Dave @ Ashcrofts said that it "should" be ok... and touch wood, it's been fine so far. I think he suggested to measure the protrusion of the bearing (on the new box) and compare it to the old transfer box.

Mine is a remapped Td5, as VVS210 says, 1st gear is now like 2nd (with 235's/7.50's) but I rarely do any towing and the extra power helps. When I do tow and it's a steep start, I just pull away in 2nd low then shift into high once moving.

3rd Dec 2017 1:16pm

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4786

Also tuned so haven't noticed any detrimental effects. As Jim says though you can always move off in low

3rd Dec 2017 1:39pm

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