 | Home > Technical > Transfer case swapping - questions |
 
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| landy andy Member Since: 15 Feb 2009 Location: Ware, Herts Posts: 5815  
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Hi/low is rod operated.
Yes splined shaft join the two boxes No you don't have to drain g box oil Yes you can do it all leaving interior complete but it is easier if removed, but quicker if you don't remove interior. Andy |
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21st Oct 2014 7:37am |
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| excossack Member Since: 22 Feb 2012 Location: North West Posts: 5894  
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Cheers Andy. Is difflock rod operated as well?
Sounds an easy job.....with a trolley jack on my back in the drive. 1999 Defender TD5 110 Regards John M0VAZ Econet Station 48 no clock |
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21st Oct 2014 7:47am |
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| landy andy Member Since: 15 Feb 2009 Location: Ware, Herts Posts: 5815
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Yes mate both are rod operated. Trolley jack on the drive is ok, BUT, it is heavy, and it is a
 as it's not well balanced. You must be careful of the oil seal in the transfer box, where the shaft from g box goes in, otherwise you will get oil coming out between the two boxes and the t box will have to come off again. Also some joining bolts are different lengths, and keep an eye on joining dowels between the boxes, as these can get stuck in either box. |
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21st Oct 2014 7:59am |
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| excossack Member Since: 22 Feb 2012 Location: North West Posts: 5894
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Cheers for the tips on the oil seals. I was aware it was heavy but not sure how heavy. I might have to think of a cradle for it. 1999 Defender TD5 110
Regards John M0VAZ Econet Station 48 no clock |
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21st Oct 2014 8:23am |
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| TDCi Guy Member Since: 17 Aug 2014 Location: Yorkshire Posts: 286 
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It's more than possible on a trolley jack if you have one with enough reach. You'd need a second person though as it really needs one to keep the box steady as the other pulls and lowers the jack. Tom
@tditomprice 100” Defender Hybrid 2010 Alaska White 90 HT |
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21st Oct 2014 8:47am |
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| excossack Member Since: 22 Feb 2012 Location: North West Posts: 5894
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I will be roping in assistance for the job
 and trolley jack has a fair bit of height on it, but would have to measure it up first. 1999 Defender TD5 110
Regards John M0VAZ Econet Station 48 no clock |
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21st Oct 2014 8:59am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17614 
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It is easier if you have access to a transmission jack (which has a bigger footprint and a flat non-swively top, rather than the swively cup of a trolley jack), but can be done with a trolley jack with care. Trolley jacks tend to be taller in the lowered position and often have less lift than a transmission jack, so you may find that once you've lovwered the jack you have to lift the t-box off the jack to get it out from under the vehicle. The t-box can be lifted by one person, but not when lying under the car!
it is also a great deal easier if you make a wedge-shaped thing to put between the jack and the bottom of the t-box, since of course the bottom of the t-box slopes. There is a special tool for this, but it is an expensive option for a one-time job. I have used a couple of bits of wood screwed together to achieve the same result without problem. Don't forget to drain the t-box before removing the bolts which hold it to the gearbox as the lower bolts keep the oil in. |
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21st Oct 2014 9:38am |
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| excossack Member Since: 22 Feb 2012 Location: North West Posts: 5894
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Thanks blackwolf, dont think I have access to one...Might have to ask around.
I was thinking of making a shaped wedge to hold the TC at the right angle to aid removal/fitting. Oil draining will be done. Just purchased the Disco transfer case...Eeeeek! 1999 Defender TD5 110 Regards John M0VAZ Econet Station 48 no clock |
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21st Oct 2014 10:47am |
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| fatman Member Since: 14 Jan 2014 Location: Athens-Greece Posts: 126  
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For your convinience,you can use 2-3 long bolts - with the head cut - bolted in place of the original bolts,it will help you a lot "sliding" the transfer case into position without worrying damaging the input seal or the case falling on your head.
The photos are from my previous disco 2,i thing it applies to defenders too.. 
Cheers. |
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21st Oct 2014 11:08am |
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| sharkey964 Member Since: 05 Oct 2014 Location: On a muddy track Posts: 579  
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When i did mine,before I took the T/B off the G/B,I took the 2 top bolts out and replaced them with threaded bar,or long bolts with the heads cut off,about 120-150mm long.So when you take the old one off and present the new one yuo are clear of the splined shaft when the T/B drops,so no stress on the seals.
I did mine with the floor in place,it's a bit fiddly to disconect the hi/lo selector though. Good luck.  |
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21st Oct 2014 11:11am |
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| excossack Member Since: 22 Feb 2012 Location: North West Posts: 5894
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I like the idea of the bolts - cheers 1999 Defender TD5 110
Regards John M0VAZ Econet Station 48 no clock |
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21st Oct 2014 11:49am |
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| barbel jim Member Since: 12 Dec 2012 Location: Northants Posts: 1434 
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Pretty simple as everyone else says
 I found the hardest bit was realigning the the splines on box when refitting. I used the long bolt method and lifted it in and out without any jacks. It is heavy and awkward but is possible
You would be alright with the chubby staying, but it is a lot easier removing transmission tunnel, especially for the diff lock rods . Take it for its initial test drive before you refit it. It will be noisey and draughty, but if things need a tweek you won't have to strip it all !! You will also need to swap your old speedo drive over and depending on the age of your current defender, there may be some electric connectors you cannot swop over easily. I believe these opperate the diff lock light on the dash, and throttle position sensativaty. I had it when I did mine, but don't miss either !! You can swap the casing around but I couldn't be bothered !  |
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21st Oct 2014 4:20pm |
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| excossack Member Since: 22 Feb 2012 Location: North West Posts: 5894
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The Defender is a Jan 99 Model so will have the Hi/Low feed and the difflock light. The speedo drive is an unbolt jobbie?
The box going in is from a 1997 300Tdi Disco so should have the difflock warning light? Taking the cubby box out might be an ideal time to have it recovered. 1999 Defender TD5 110 Regards John M0VAZ Econet Station 48 no clock |
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21st Oct 2014 5:03pm |
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| barbel jim Member Since: 12 Dec 2012 Location: Northants Posts: 1434
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Speedo drive is simple, believe they are colour coded , but swap for yours to keep speedo accurate. Not sure if it will have the feeds for warning lights or not. Mine was from a V8 disco, and no senders for me. I just taped the wires up out the way. I still have my old box, and could refit it if my usage changed, or the box fitted developed a problem. My theory was to change internals to make it 1.2 and refit, but so far it just sits on the floor of the garage! There is a good photo guide on lr4x4 by Les... Aka white90 sorry can't link as on the iPad and don't know how
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21st Oct 2014 5:14pm |
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