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2hel

Member Since: 28 Nov 2022
Location: Essex
Posts: 175

1.4 to 1.2 Discovery transfer box

Hi all, hopefully those that have done this can help, I purchased a Discovery 2 transfer box with the diff lock to put into my 90 TD5 and I just wanted to know if it's meant to be a direct replacement as when I went to change they did not look identical as such? This scared me and I bailed on the process

I am struggling to find a good tutorial / video of the process when changing to this transfer box

Any help / guidance appreciated

27th Jun 2024 10:29am

rustandoil

Member Since: 08 Sep 2012
Location: Cotswolds
Posts: 711

2005 Defender 110 Td5 XS DCPU Bonatti Grey

Britanica restorations on Youtube ....

https://www.youtube.com/c/BritannicaRestorations

27th Jun 2024 11:25am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17192

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

They're not identical but are essentially interchangeable.

Disco2 has a larger diameter front drive flange (so swap it with the Defender one), due to the larger flange the front output casing is different (no need to worry about this), and round the back the speedo drive facility is missing from the Disco2 box since the Disco uses the ABS wheel sensors for the speed signal (so you'll need to swap the parts from the Defender box).

You will also find that the operating levers for the difflock and high/low selectors are different (I can't remember what the Def TD5 uses but the Disco uses cables no rods) and possibly the connectors for the associated switches differ.

So they are definitely not a direct swap, you will need to swap parts over.

27th Jun 2024 12:41pm

Dinnu

Member Since: 24 Dec 2019
Location: Lija
Posts: 3330

2012 Defender 90 Puma 2.2 CSW Santorini Black

I replaced a transfer case on a later Puma with one coming from an automatic Disco 2 (if that makes a difference). I cannot remember the front out put flange as Blackwolf mentioned, but clearly remember that I swapped the rear output housing complete with the shaft that goes to the center diff and the high/low housing as the lever on the Defender is cranked with small ball joint.

There will probably be other sensors/switches on the Disco box which the Defender not use. Simply left unconnected.

Handbrake assembly kept the original Puma. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black

27th Jun 2024 3:41pm

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