Thread: Discovery/Defender Transfer Box

Originally Posted by landy

You are the right man to talk to.
As you have two essentially the same vehicles what are your thoughts/observations on the two cars in regards to the gear sets.

Pretty much as per the previous post , if I had the disco gearing in the work 130 it would be a total PITA

So I decided that the best course of action would be to rebuild the Decovery TC and keep the original Defender TC in the garage as a known spare should I not like the gearing or blow the TC and need another.
I laid out all the Ashcroft parts and made sure I had everything I needed and then stripped the D1 TC.. It's essentialy scrap!
1. There was no preload on the intermediate gear cluster. In fact it had 1.023mm end float. This has coursed significant gear contact wear.
2. The intermediate gear pin is oval and has worn the TC bore oval and has significant wear.
3. The input gear is a Defender (has dog teeth) gear but not crossed drilled and has some spline wear from lack of lubrication.
4. The peened nut at the end of the centre diff was loose but peened. The gear was therefore a loose fit and has worn a significant groove into the bearing surface
5. And both the front and rear drive shaft flanges have grooves worn by the seals in them and I doubt they'll ever seal oil.
Plan B is to replace all the bearings and seals and fit the centre diff cross shaft to the Defender box. I'll leave the gearing as is so I don't stress the car more than necessary while towing.
All in all, crap Sunday!
First world problems haha.