 | Home > Technical > Swapping Transfer Box, how hard is it? |
 
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| Alex1976 Member Since: 23 Jan 2013 Location: Buckingham Posts: 596  
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It is just a big heavy lump to shift around, but technically not difficult.
I wouldn't bother with an engine crane - I used a transmission jack which was much better. I got my one on ebay for about £90 and its done two gearbox swaps now. Its like a small scissor type jack that goes from 100mm to 500mm wound up with a 1/2" drive socket. For a straight swap you don't need any seals, but do put a ring of silicone sealant around the mating surface of the box where the drive shaft goes into the gear box. I swapped to a 1.2 tbox that I got from Ashcrofts and it does make it cruise so much better. |
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15th Jan 2014 9:59pm |
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| dnorrishill Member Since: 15 Jul 2011 Location: Hampshire Posts: 615 
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Alex, thanks for the info.
There are a few transmission jacks on ebay like this: http://www.ebay.co.uk/itm/DRAPER-53095-FLO...29ff7e8c20 They seem to be rated at a max 150kg, is that enough for a transfer box? |
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15th Jan 2014 10:19pm |
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| Lambley Member Since: 20 Apr 2013 Location: Mid Devon Posts: 1435  
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I did mine about 6 months ago, best mod I've done so far, much nicer to drive in general, I don't do much towing so its great.
I was lucky because I have a local garage that I'm friendly with, they let me use their pit for the day and gave me a lift with the heavy lift, you ideally need a helping hand when taking the transfer box on and off, other than that it's fairly straight forward, as long as you get a bolt or nut back on the top you can stop sweating while trying to balance the weight. I'd recommend changing the seals at the same time, it only takes 5 mins to swap them over while you have things apart. Best of luck with it. |
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15th Jan 2014 10:33pm |
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| Alex1976 Member Since: 23 Jan 2013 Location: Buckingham Posts: 596
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Yep - thats exactly the jack that I used to do mine. It carried the weight of the tbox no problem. I would say the tbox weighs about 60Kg so well under the max weight of the jack.
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15th Jan 2014 10:43pm |
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| diesel_jim Member Since: 13 Oct 2008 Location: hiding Posts: 6093 
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Depending on how strong you are, you might not need a jack. Or if you've got an able helper to give you a lift up & down with it, the rest is just nuts & bolts.
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16th Jan 2014 7:21am |
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| Nidge Member Since: 27 Jan 2008 Location: Kildare Ireland Posts: 818  
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He you go pics and all -
http://forums.lr4x4.com/index.php?showtopi...ntry150884 N. |
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16th Jan 2014 8:44am |
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| NickEJ Member Since: 24 Nov 2012 Location: Ljubljana Posts: 152  
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That's the best series of "how to" photos I've ever seen. Well done Nidge! Might do it myself now.
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16th Jan 2014 9:13am |
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| dnorrishill Member Since: 15 Jul 2011 Location: Hampshire Posts: 615
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Unfortunately I have neither the strength (sit at a desk 5 days a week) nor a willing helper at home! |
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16th Jan 2014 12:30pm |
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| diesel_jim Member Since: 13 Oct 2008 Location: hiding Posts: 6093
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Good pictures in that thread above, however they seem to overdo things a bit....
as in, there's no need to remove the input gear from the back of the t/box. when you undo the t/box from the main box, the shaft just slides out on splines. same with re-fitting. Taking the handbrake off is useful as it's quite a heavy bulky thing bolted to the transfer box, so good to get it out of the way. |
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16th Jan 2014 5:58pm |
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| Dieselhead Member Since: 21 Oct 2012 Location: Pulborough. West Sussex Posts: 552 |
If you get the bits
Drive it over to my place & we will give you a hand to swap it over 
Couple of hours work me thinks 
A mate has a D2 which hes going to break up very soon. Why dont you buy the T box & just swap it over??? Chris 2008 XS 110 2.4 Utility. Tonga Green 1953 Series 1 for restoration 1983 Mini Mayfair 2004 VW T5 Camper 2008 Diahatsu Sirion. Thats hers Classic Bolens Garden Tractors |
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16th Jan 2014 7:46pm |
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| dnorrishill Member Since: 15 Jul 2011 Location: Hampshire Posts: 615
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Seriously, wow if the D2 has a diff-lock you will be my new best friend!! Let me know, but that would be brilliant, thanks very much. |
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16th Jan 2014 8:39pm |
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| Brucey Member Since: 18 Jul 2012 Location: Warsaw, Poland Posts: 61  
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I swapped my box (well the gears inside) by hand without lift or jack. In hindsight it was as mistake as I was short on time.
One thing to check which doused me a great deal of swearing  If you are using a different gearbox or transfer box make sure that you have the locating dowels in place correctly before you try to lift it into place. I did not and found that I could not get the gearbox/transfer box to mate together  as I had two male dowels. It is easy to see now, but lying on your back trying to press the F**king thing into place with rust in your eyes it was not so easy  .
Bitter, me? never! Chris Defender 110 DC converted Auto BMW R1200GS BMW F650GS Dakar |
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17th Jan 2014 8:17am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17430 
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It isn't difficult to swap the difflock from the Defender box to the Disco box if the Disco box lacks the internals once both boxes are out. Disco2 boxes with the difflock are not easy to find! Took me a long time to find one to donate the parts to retrofit the lock to my Disco. |
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17th Jan 2014 8:59am |
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| Dieselhead Member Since: 21 Oct 2012 Location: Pulborough. West Sussex Posts: 552 |
Ahh yes the diff lock
Not sure if the D2 has it. Its an auto which is cooked. I will find out next week & let you know Chris
2008 XS 110 2.4 Utility. Tonga Green 1953 Series 1 for restoration 1983 Mini Mayfair 2004 VW T5 Camper 2008 Diahatsu Sirion. Thats hers Classic Bolens Garden Tractors |
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17th Jan 2014 4:43pm |
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