Have you considered fitting a Puma gearbox, think I saw a kit on evil bay some time ago.
Travelled from Karratha to Geraldton in the last 24 hours or so
2002 TD5 Defender with transfer case that was rebuilt 12 months ago
Travelled at about 120 Kmh (on the clock) with strong headwind and high temperatures
The transfer oil was running up to 98 degrees C this is with an extended sump and Castrol Syntrans.
I have often thought of buying an overdrive but with the manufacturer saying keep the temp below 110 degrees C
I just can't see how they would cut it under these conditions
I suspect a modified Ashcroft R380 with a different 5th gear ratio would be the way to go.
 Master
					
					
						Master
					
					
                                        
					
					
						Have you considered fitting a Puma gearbox, think I saw a kit on evil bay some time ago.
 Wizard
					
					
						Wizard
					
					
                                        
					
					
						Can some one explain how altering the gearbox will lower TC tempsapart from the contact between the two contact faces
AM
Last edited by Ancient Mariner; 6th December 2014 at 10:56 AM. Reason: Added extra
They do seem to run hot here in Oz. I've got 200hp and 5.9 litres hooked up to my LT230 and so far it seems to be taking it. Same as you, I've got the Ashcroft extended sump, but I've also put a piece of 3mm plate between the box and sump to help keep the casing from spreading under load. Also contemplating fitting two unions to the sump and locating a cooler somewhere on the chassis which will increase the capacity again.
1995 Mercedes 1222A 4x4
1969 (Now know! Thanks Diana!!) Ser 2 Tdi SWB
1991 VW Citi Golf Cti (soon to be Tdi)
'When there's smoke, there's plenty of poke!!'
'The more the smoke, the more the poke!!'
Lower the ratio (higher speed) requires more torque to drive the box, and that increases the load thus increasing the temp... The old 1.667:1 box in a 2.5 diesel 110 was always cool as the vehicle was flat out at 90kph and had stuff all power.. The 1.003:1's always run hot as they are in a Range Rover being driven flat out with 100+hp at 120+kmh. Might be totally wrong with what I've said, but think Im along the right lines.
1995 Mercedes 1222A 4x4
1969 (Now know! Thanks Diana!!) Ser 2 Tdi SWB
1991 VW Citi Golf Cti (soon to be Tdi)
'When there's smoke, there's plenty of poke!!'
'The more the smoke, the more the poke!!'
AM my reference was to the Roamer drive
The design of the box generates more heat than the standard gearbox
If I only have 10 degrees to play with then the elliptical gear train will have no hope in light of the amount of heat it will generate
 Wizard
					
					
						Wizard
					
					
                                        
					
					
						TC ratios , Tyre sizes ,Diff ratios , loads and conditions, oils all have a bearing on TC temps .The gearbox stuff all with a direct drive no overdrive being the coolest
AM
AM the overdrive bolts onto the transfer case where the PTO would normally go
They also have a common oil supply
My point is for my conditions I should forget the overdrive
Interestingly the R380 was a constant 12 degrees cooler than the TC
 Master
					
					
						Master
					
					
                                        
					
					
						I think you have mixed up your ratio's and speed results.
If you put a higher ratio box or T/C in place of a lower one, then at any given speed under similar loads like hills ( before and after the box or T/C change ) you will be back a gear. So once you were in 4th , you are now in 3rd, ( unless you also increase your engine power significantly at the same time).I recently went from a lower to higher ( or taller ) ratio setup, 1.4:1 to 1.2:1 in the T/C and my real world result is that I have lost 1st gear and gained a 6th !
Once I might have gone down into 4th I now go down to 3rd so the load on the gears generating heat should be similar according to the above reference.
At the end of the day I think the biggest factor on heat build up is the 2.5 tons of scrap metal pushing a head of air with next to no help from aerodynamics.
 Wizard
					
					
						Wizard
					
					
                                        
					
					
						I am a bit confused here (not unusual) You have an R380 an OD box and you want to add an OD on the TC The only advantage I can see would be to save 5th in the R380 by running direct But the Roamer drive is an extra complication which will raise the TC temp If you were considering using both overdrives You are going to need something better than a TD5..I run 3.0 diffs,1.003 TC gears and a mxa5r GB in my 110 Top speed about 180 kph. I run EP85--140 oil in the TC as well as the diffs and as you can imagine the TC runs fairly warm As long as the oil is not showing a burnt colour I am not too concerned as the oil recommended for hotter conditions
AM
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