Discovery 1 transfer case replacement

**PV5150** · 16th April 2016, 11:40 AM

Hello all

I have a 1993 200Tdi Discovery 1 with an LT77S 5 speed transmission. However, the transfer case (serial no.28D288234E) is starting to show her age with some interesting noises and a consistent oil leak. The manual transmission was rebuilt around 25 - 30k kilometres ago and is going like a champion. Ultimately I would like to rebuild my sick transfer case at my own leisure and just grab another healthier transfer case in the interim.

What I would like to know is :

1) I have found a potential transfer case as a donor but it comes from a 2002 Disco 2 v8 but I'm not sure if it would be compatible. Would it be usable if I were to get the large cog from the output shaft of the donor vehicle gearbox at the same time, in order to keep the same number of teeth, width of teeth/spline etc? My existing cog isn't the cross drilled one and I would like to prevent any further spline wear.

2) Do I need to grab the front and rear tailshafts from the v8 donor as well or am I able to use my existing ones?

3) If this tc isn't able to be used, approximately what age should I be looking at? Does it have to come from a diesel engine or is a v8 variety still a viable option? I'm in Tassie so does anyone know of a suitable tc that's available?

4) If I'm not able to find a spare tc then I'm going to have to rebuild it as soon as possible as the vehicle is a daily driver for me. I've contacted a local vendor for a full rebuild kit price ($360.88) and I'll be checking Ashcrofts as well. I'm quite handy with the spanners and helped rebuild the gearbox but would you say the the transfer case is easier to do? The only tool I'm lacking at the moment is the press and the tool for checking bearing preload but I'll more than likely drop some dollars at an engine rebuilder to get them to put on for me.

Thank you in advance and kind regards

Matthew :-)

**loanrangie** · 16th April 2016, 06:33 PM

Although the D2 transfer will physically fit , one from another D1 would be better as it will have a working CDL which a 2002 D2 wont have.
Keep your current shafts as D2 shafts are different, they have a double cardan up front and a roto flex coupling in the rear.
Both can be worked around but not worth the effort since a D1 transfer will be a better solution for you.

**PV5150** · 16th April 2016, 07:47 PM

Originally Posted by loanrangie

Although the D2 transfer will physically fit , one from another D1 would be better as it will have a working CDL which a 2002 D2 wont have.
Keep your current shafts as D2 shafts are different, they have a double cardan up front and a roto flex coupling in the rear.
Both can be worked around but not worth the effort since a D1 transfer will be a better solution for you.

Thank you so much for responding loanrangie. I'll leep my searches specifically to D1

**Roverlord off road spares** · 23rd April 2016, 10:21 AM

A D2 transfer will not have a speedo outlet, you will have to take your existing casing part from your D1 transfer and fit it to the D2 transfer case.

**PV5150** · 24th April 2016, 09:15 PM

Originally Posted by Roverlord off road spares

A D2 transfer will not have a speedo outlet, you will have to take your existing casing part from your D1 transfer and fit it to the D2 transfer case.

Thank you. I've managed to find a Discovery 1 TC that is in twinkly good nick - I had to take the one out of my old one and put it in the new one.

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