Thread: Disco transfer box into a TD5 Defender

In a word, brilliant. Low range unchanged, highway...2000rpm at 110 kmh, much quieter. I never though drive up hills in 5th even though vehicle will do it...too hard on the box and transfer case.

I have had no problems with my TD5 towing 3500Kg, but it improved the fuel economy and pulled better than I expected it to after one of Jose tunes. Never have it in 5th for towing as 4th does the job nicely

I've not done the exact thing you are looking too but I've (amongst other mods) swapped out a transfer for the ratio change: I used to have a 1:1 and went back to a 1:2. (this was on a 4DB1 however)

The biggest problem I found with the higher transfer ratio was that first gear was too tall. A pain in traffic as at idle was always faster than anyone who was moving forward at lights etc and found I had to leave really large gaps in front of me and in carparks you were always in the clutch or in low range.

just something to keep in mind - don't forget to keep an eye on 1st when you are playing with the ratio calculators.. like I did

Without running the numbers I'm guessing it's close to running 255/85's with a 1.4:1 t/case ?

If so I've found the gearing almost ideal in a tuned Tdi on the highway, but first is too tall for towing, you need second/low range for that.

Don't do it.

The gearing is too high, coming from a manual td5 Discovery driver with 32's... my car is chipped, I/C'd, boosted etc, and all I want is my stock gearing back..!

Just some added info...

*Yes there are numerous changes in the actual transfer case housing, but keeping year for year, you generally wont have an issue.

*I normally just change out the hi/low gear set itself, this is normally due to the fact I've removed the transfer case to rebuld it.

*A TD5 (stock tune) in a Defender with stock Defender tyre size (235 85R16) running Disco 2 hi range in something like a 90, 110 with not much else on it, tow a trailer here and there, as some have said is a good mod to do and you are going to be happy with the lessor scream at higher speeds, better again if you are only running 31in tyres (31 x 10.5R15).

*If you have a 110 or 130 with lots of gear on in, for example my dads TD5 130 with everything on it weighs in at 3 ton with 265 tyres and tows the odd bobcat, Land Rover or Jeep, then you will hate it.

Regards
Daz

Thanks for some really useful info, lots to think about for and against.
Its a 90 so doesn't carry a lot of weight and the camper fully loaded weighs about 2t which gets used maybe once a month.

Be advised: It will render your Cruiser Control, if fitted, useless though (wont work).