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Thread: Deefer output housing and internals into a D2

  1. 4th January 2009, 10:28 PM #1
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    ozscott
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    Deefer output housing and internals into a D2

    Hi all - managed to source a transfer case off an 04 Defender - lost its oil and got burnt bearings etc. Now have the case and output housing with all internals. Can anyone see any dramas in fitting the output housing and internals to my nippleless 02 D2 to get the centre diff lock in situ again (and then using a push pull lever or 04 shifter etc to activate it). I assume that the Deefer lock/unlock switch is the same as the D2 and should activate the dash light.

    Cheers and thanks
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  2. 5th January 2009, 07:38 PM #2
    Bush65
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    I haven't had anything to do with D II so could be wrong.

    Assuming that you are not changing the rear output, speedo should be ok.

    With the defender front output, you will need to swap over the disco II flange for the double cardan joint on your front drive shaft.
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  3. 5th January 2009, 10:38 PM #3
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    I know of people that have fitted Defender transfer cases to their D2's.
    This then compensates for larger tyres & brings high range back closer to factory spec.

    The only drama you should have is if you are still running close to stock tyres.

    I am sure there are others on the site that will be able to explain it better.

    Regards

    Chuck
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  4. 6th January 2009, 02:19 PM #4
    Bush65
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    I wouldn't mix defender gears with you disco gears.

    Hi range has different ratio between defender (1.41:1) to disco (1.22:1). Lo range is same ratio, but Land Rover had a tendency to change helix angles and pressure angles. They also used different gears in the LT230Q (quiet gears).

    Also if the defender t/case was run without oil and cooked, then you will most likely find the gears will be noisy.

    You should be able to swap front output shaft, centre diff and diff lock - not sure about rear output shaft as there were changes with speedo drive/sensor that I'm not familiar with.
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  5. 6th January 2009, 03:15 PM #5
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    Cheers John - thats very helpful matey. So to get CDL back in my 02 I need the internals from the output housing and they should be ok from this defender?

    Cheers
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  6. 6th January 2009, 07:37 PM #6
    Bush65
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    First thing is to check the condition of the defender t/case that was run with little or no oil.

    It helps that the the output area is in the lowest part of the t/case and could have been lubricated for longer.

    But lubrication of the rear output shaft and hardened steel bushings is one of the weaknesses in an LT230 - you might want to look at my thread about improving the lubrication to the output shaft. I would assume you will use your disco rear output assembly and can use your disco front output shaft if there is any doubt.

    The pinons and their thrust washers in the centre diff also suffer from poor lubrication - usually this is a problem because people spin a front wheel with the centre diff unlocked.

    I'm not that familiar with disco II's and year models when such and such was changed. But I assume you can use your disco centre diff (hemisphere, side gears, pinions etc.).

    The difflock mechanism in the front output housing should not have suffered from lack of lubrication.

    I expect you would replace the bearing and seal in the front output housing.

    BTW, you can easily do all of this with the t/case in situ - make sure you loosen the nut that retains the front drive flange before you pull the output housing assembly.
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