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Thread: Rebuilding an LT77 Gbox out of 1991 Discovery

  1. 31st July 2010, 07:14 AM #1
    Freestyler Guest

    Rebuilding an LT77 Gbox out of 1991 Discovery

    Hi All, I have just about finished the 4.6 V8 convertion in my Fathers 1990 V8 county and will be attacking Mum's discovery next. The Gbox has been noisy for a while but got a lot worse all of a sudden. Since it has 530,000kms on it we bought another box that has only done 270,000kms. Is there any tricks, traps, minor upgrade or anything else that could help? I have rebuilt several transfer cases and am pretty right with them.
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  2. 31st July 2010, 09:18 AM #2
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    MacMan
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    Removing 5th gear is entertaining, but otherwise you'll get by with mostly standard pullers.

    I've fabricated a few bits and pieces to make life easier, including the stand shown in the RAVE manuals / WSM.

    On close examination I found that the 1st/2nd hub and sleeve needed to be replaced, and it's worth checking the dogs on all the gears especially 1, 2 and 3 since they do the most changing.
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  3. 31st July 2010, 01:07 PM #3
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    BigJon
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    It is common to replace the LT77 with an R380. Well known to be a stronger gearbox.
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  4. 31st July 2010, 04:15 PM #4
    cewilson
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    May be common but I'd just rebuild it.

    Considering it's done 530k on it, and I've got one in my Defender that's done over 500k as well - I don't consider it to be that weak!
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  5. 31st July 2010, 04:17 PM #5
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    BigJon
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    Fair enough too. I have one in my RRC, but it has been rebuilt in the past. I think when I fit my stroker engine I will upgrade to an R380.
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  6. 1st August 2010, 06:39 AM #6
    Freestyler Guest
    The Disco is mainly a road vehicle to us, is does do some 4x4ing but nothing hard. Thats what the County's are for, and after the 4.6 EFI conversion in Dad's truck a straight swap would be good. I want to get onto putting the Maxi Drive in the back of my truck!
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