Defender LT 230

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Originally Posted by DazzaTD5

just to add...

While I have a local machinist do mine cases, its 3 or 4 cases at a time due to the setup rather than the actual job thats time consuming. also due to his workload its generally round a month.

What I recommend to the OP is simply buy a empty case that has the steel insert already done from Ashcroft in the U.K

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I'm not sure that setting up a second and subsequent housing in the mill would be significantly less time-consuming than doing a single one, the case has to be clocked in precisely each time. Like many milling jobs, the setup is a large portion of the job.
One of the great things about having the equipment is not having to put up with the 'yeah mate, I can do that in about 8 weeks'.

the defender front output flange and D2 front flange are interchangeable. before the days that GL started selling a defender flanged double carden, the only option for a Defender was to swap the flange to a D2 style and use a factory D2 shaft or an aftermarket shaft like GL or TW with a D2 flange. As for length, many ran a factory D2 shaft on a stock height defender. If it's lifted, you might be more cautious as to spline engagement at full droop.

as a side note, the defender front output spline count is the same as that used on a Ford 9" diff. As such, you can use a Ford 9" pinion yoke on a LT230. More relevant for those with clearance issues like with a 4L80 tranny.

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Originally Posted by POD

I'm not sure that setting up a second and subsequent housing in the mill would be significantly less time-consuming than doing a single one, the case has to be clocked in precisely each time. Like many milling jobs, the setup is a large portion of the job.
One of the great things about having the equipment is not having to put up with the 'yeah mate, I can do that in about 8 weeks'.

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No doubt you are likely correct, I'm not a machinist nor do I intend to be one.

To correct my original post, its more likely I hate to get one off items done, if I am going to get another business to do a job for me I want multiple of them done that way my jobs are worth doing. Another job is machining of the adaptor shaft between the MT82 box and the LT230 box, I get 10 done at a time, I would expect he has them done prolly in an hour or two which equates to a good job for him.

While other businesses are doing my "good jobs", I'm doing jobs that I consider "good jobs" that pay my bills...

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Originally Posted by POD

Just something to note if you look at that old thread of mine that Roverrescue has quoted, where I did my first couple; the bush does indeed need to be stepped. My first one migrated inward despite installing it with 'permanent assembly' loctite (don't know about the other couple I didn't step!). Live and learn, they say. The gearbox will stop it migrating outwards, so the stepped bush needs to have the larger diameter to the outside of the housing.

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Hi Pod,
Could you update the other thread as well with stepped bush info.
Just to keep the info current.
Tony

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Originally Posted by TonyC

Hi Pod,
Could you update the other thread as well with stepped bush info.
Just to keep the info current.
Tony

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Done as requested.

Just an update for those contemplating the job, an excellent job done by Harris engines for $150. Leak fixed