Thread: Transfer case

LT230 in both cases and yes, interchangable.

Originally Posted by brad56

Hi all can any one tell me what model transfer case are fitted to a manual series 1 discovery & auto series 1 discovery
regards to all
Brad

just be aware that there are suffixes to them. like LT230T and Q. slight differences between them but if doing any work to them just be aware that different workshop manuals refer to different versions of the cases.

i learned this the hard way

Originally Posted by Fausto79

just be aware that there are suffixes to them. like LT230T and Q. slight differences between them but if doing any work to them just be aware that different workshop manuals refer to different versions of the cases.

i learned this the hard way

The Q has gears in it like a sewing machine there crap

Originally Posted by Blknight.aus

LT230 in both cases and yes, interchangable.

Thanks Dave.
I have just buggered , I think, my Tbox.
Low in oil and it came to an abrupt stop. Locking up.
Filled with oil, drove it for a bit, no noises, then it locked up again.
I have a T box off a auto V8 and mine is a manual TDI , so I can just swap over OK?
Can I swap T boxes without removing the main Gbox , and do it all under the car?

Keith

Originally Posted by 123rover50

Thanks Dave.
I have just buggered , I think, my Tbox.
Low in oil and it came to an abrupt stop. Locking up.
Filled with oil, drove it for a bit, no noises, then it locked up again.
I have a T box off a auto V8 and mine is a manual TDI , so I can just swap over OK?
Can I swap T boxes without removing the main Gbox , and do it all under the car?

Keith

Hi Keith,

not sure about the v8 box removal but i can tell you i have removed tcase on its own from a tdi manual. in hindsight, would have been easier with the gearbox and all. some fidgity moments trying to remove all the linkages and breather pipes etc. far easier when the whole thing is out of the car. it is however possible.

it takes a fair bit of manouvering with jack up and down. you will need to move the exhaust out the way. i disconnected it from the down pipe and all the mounts to the back of the car to move it out the way. took off rear tailshaft completely (mark it up!). also the rotoflex joint should come off with the shaft according to the manual. i did it the other way round. the front shaft can just be undone at tcase and then cable tied out the way.

mark all the bolts you take out from the gearbox to transfer (6 of). they are all different lengths and need to be put back in the right places.

as i mentioned though. if i were to do it again i would take the whole assembly out gearbox and tcase in one and put it back in one. i left crossmember in though and tried to lift tcase up over the mounts and then back down and back. if you removed xmember you need jack to support the weight which gets in the way.

when i put it back in as a whole unit i used a steel bar in the cabin with a ratchet strap around the boxes to support it whilst i removed the jack and put the xmember back. so maybe you can do it this way if you want to take the tcase out alone. it certainly would be far easier without the xmember there. in retrospect.

PM me i can send you my number and explain it a bit more. kinda hard typing on here and trying to remember everything. there are a few things that caught me out. ill post again in a minute with the thread i started about the same topic. has some useful info on it.

if you get some long bolts (i will find out the size in a minute) and cut the heads of them and screw them into the top holes of the gearbox. use them to line up the two boxes when putting back together (or pulling them apart) so that you dont damage the seals. i detroyed one of the seals pulling them out. whatch that you dont damage the seat that the seal sits on.

also, remember to epmty the oil out of both boxes. makes it a few kg lighter and more stable and may save you from making a big mess too.

sorry if ive stated obvious things to you. just trying to pass on stuff which ive learned from the wise ones on here.

http://www.aulro.com/afvb/discovery-...380-lt230.html

m10 are the bolts you need. get long ones and cut the heads of them. if you are pulling only the tcase out though if the bolts are too long you will not be able to slide the box back far enough before the lever hits the opening in the cab.

also helps if you pull of the cover from the gearbox lever, metal one with 4 screws as this comes close to the tunnel and without it you can manouvre the boxes a bit more.

pull both boxes out. easier. believe me. i did it the hard way.

Swapping out a transfer case is quite easy without removing the main gearbox, so long as you do a few things. If you have one of those extended finned sumps, that makes a good jacking point for your trolley jack. Otherwise make a flat steel plate that attaches to some of the sump plate bolts with a few legs to provide a level jacking point. It can also have a guide pin under it to positively engage the trolley jack head, to stop the TC falling off the jack.

Remove the hand brake back plate and hang it up out of the way, you don't need to disconnect it. Drill out the rivets holding the tunnel cover on, undo the transfer case shift lever. Your two guide studs you made out of M10 x 150mm bolts will allow you to slide the box on and off the gearbox without wrecking the seal in the front of the TC.

Two people should be able to swap a TC in a couple of hours. One person may run out of hands unless he's good.

Originally Posted by bee utey

Two people should be able to swap a TC in a couple of hours. One person may run out of hands unless he's good.

or a hindu god.

good point on the extra capacity sump on the tcase. pulling it out i didnt have one. putting it back in i did and made life easier. although i put both boxes back in one.