Thread: Defender transfer case gear up 1.41. to 1.22

Thanks you very much guys wizard, ininformed, dero, eddy, 85 county et all.

I just got he benefit of 50 years experience, so i feel i can make an informed decision, thankyou.
I'll go ahead if i can get the D-2 TC, but 85 county's point is well made, about slogging it out in 5th gear at high torque scenario. It's not really my style, a car has a gearbox for a reason so you can keep the engine in comfortable power & torque range, I've been driving small engined cars all my life, ( too stingy to buy something with a big engine). They need some revs to give any sort of power, "if in doubt change down " Because I only travel at 100 km/h, if the engine is struggling I can change down to 4 th, with the 1.22 gears it will bump up the revs. The comments of those that have done the conversion are pretty much what i expected, it wont' pull up long hills heavily loaded or with big head winds etc. no problem I'll just go back to 4th. I can tell when the engine is comfortable by the EGTs and the boost pressure. It' s a factor in Australia the distances we travel are fairly big so comfortable cruising for the engine and passengers is important, so steady cruising at 2800 rpm should be good. cheers simmo

Originally Posted by rijidij

but it will accelerate up those long inclines in 5th gear rather than struggling up them.

Originally Posted by 85 county

now why would you want do risk that??

I do usually throw it back to fourth for the sake of the gearbox, I was just indicating the extra power/torque will easily handle the 1.22 gearing.

Cheers, Murray

I've recently had the TC gears changed from 1.4 to 1.2. I have a Td5, chipped, bigger intercooler, and a VNT from Bell. I'm also running BFG Km2 255/85/16.
I have no problem taking off, even with a 2.5 tonne dual axle trailer, plenty of grunt. If anything it's a bit scary how fast the deefer wants to go now.
100kmh is at 2080rpm and its pleasant to be inside the vehicle. I drive with my egt gauge and the fuel economy whilst fully loaded with camping gear and surfboards on the roof rack, sitting mostly on 110kmh for 7300km from Tassie to western south oz and back averaged 10.6 lt per hundred.
Last year same trip, same amount of gear over 6900km I averaged 12.9, the difference being the VNT and the TC ratio change. Plus when I got home I was sick of the noise of the Td5 revving its ring off.
For me, the TC ratio change and VNT was money well spent, but I only did both because the original turbo popped as did the r380 lay shaft bearing, so while it was out, the vehicle got new clutch, DMF, and ratio change. The gears were from a 08 puma lt230q.

Cheers Bob

Originally Posted by simmo

My apologies gentlemen and ladies, I did try a search on this "transfer case gears", but couldn't find anything on it. I'll be fitting a Mad Man VNT turbo kit in June, and looking at the torque curves I'm going to have a lot of extra torque up to 3000 rpm, so I want more relaxed cruising at 100 km/hr. I toyed with the idea of a roverdrive overdrive , but it's expensive & and added complication. I 've read somewhere, I think quite few of you have changed your TC gears to the higher ratio 1.22, from the discos. I'd like to do the same, did you just change the gears or did you change the whole T box? My preference is to change the whole box. Another member has a T-C from a disco 2 for sale. has anyone a similar experience using the disco 2 transfer case? I figure we could have a quick look inside at the center diff to makes make it's Ok. and them put it straight in. Its amazing how the project has budget "creep" or " growth". but after 15 years I don't mind spending a bit on her. say $2200 for the kit landed, xxx$$ for the transfer case + labor fitted, $600 for some exhaust mods. ( it will be the car the TDi should have been by 1995 ). My guess is we're going to not have a lot of beer money left from $4000. But for me It's good to have an offroad car you can use and not loose sleep over dirt, water, dust etc. So I appreciate your advice about the project, I''l keep you updated about how the budget is going. cheers simmo.

I have an lt230 transfer case sitting in the garage if you are interested pm me, I haven't got round to advertising it yet. It is a runner but a bit worn, perfect for a rebuild.

Some info about the LT 230 & R380 Fyi

Look at the 5th gear ratio, you can change that according to Ashcroft's i.e. put 5th gear set out of a V8 R380 into a diesel R380. That will gain you a little in lowering the revs.

As for that pdf Simmo, not sure but the rpm doesnt seem right. Im pretty sure my truck is not doing 3406 rpm in 5th at 65mph.

Seems my engine must be leaving a lot on the table compared to other members here. Even if I could get the power out of it to match, I have had enough problems keeping the engine in a safe cool zone towing here in SE Qld.

And not just the extra power adding the heat, but those towing with bigger tyres and the higher gear sets. Thats more engine load.

I did the complete disco T/C swap to my chipped, and bigger intercooler TD5 130 dual cab about 40K km's ago.
At the moment Im running 285/75 x 16 tyres and it handles is fine , even when towing my off road Jayco van .
1st gear can be a bit tall when taking off with the loaded van on a hill but it's way better cruising on the highway and noticable quiter in the cab on the highway.
But if change up to 35"s i'll rebuild and fit my old T/C as in my opinion it'll be over geared.

Originally Posted by Kappa130

I did the complete disco T/C swap to my chipped, and bigger intercooler TD5 130 dual cab about 40K km's ago.
At the moment Im running 285/75 x 16 tyres and it handles is fine , even when towing my off road Jayco van .
1st gear can be a bit tall when taking off with the loaded van on a hill but it's way better cruising on the highway and noticable quiter in the cab on the highway.
But if change up to 35"s i'll rebuild and fit my old T/C as in my opinion it'll be over geared.

There's no way a Tdi, even with the fuel turned all the way up would pull that gearing in first, high range.

I'd reckon I'd fry my clutch in no time.

IMO the stock 1.4:1 t/case plus 33.3" tyres is about right on the highway while being a pain in first and needing second/low for trailer take offs on hills (or when dead cold)