Disco 2 transfer case into defender
putting back the drive shafts and linkages took longer than I thought it would. About 5 hours, thursdy night and friday morning. We had to change the Hi low selector to the defender one the lever has much more offset than the disco -2 one, and its trickey to get the gear lever mechanism connected. My defender doesn't have a hi lo range lamp, so we left the switch disconnected.
I also put the disco hand brake drum on instead of the defender one, its half the weight, that should make the life of the rear bearing a bit easier.
The TC is filled with semi synthetic 75-90 penrite transgear.
Packed up the car and finally got on the road to Hervey bay about 930 am.
The higher first gear was a little noticeable at first but not really an issue.
I seem to be doing less gear changes than before and rarely change into 5th around town, and use 4th gear a lot more.
On the highway, a big reduction in noise, I can hear wind noise now, and can easily hold a conversation with my wife. Touring is much more relaxed affair, keeping up with the traffic no problem, cruising at 100 -110 kms hr. ( its never going to go like a Td-5) The car can pull up all the hills on the pacific highway in top gear and maintain 100 kms /hr, the combination of the VNT and disco TC case is a good one. (add air bags on the back and its pretty good all rounder.) Counting the cost of the ashcroft ATB, I would say the cost of buying and rebuilding the disco TC was about $1500.
Fuel consumption is improved, ( even though I'mm probably averaging 5 km/h faster than before ), I used my 42 liter reserve tank as the test tank, 430 kms from about 40 liters. about 9.5 l/100 mostly on the pacific high way Brisbane to Hervy bay, with some urban driving at each end. We did 800 kms all up on the weekend and still had just over half of the main tank left.
Stopped a few times to check the temperatures with the IR gun, the TC sump cover was 55 -60 deg, and the front housing about 65- 70, rear housing about 55. R380 was running about 75 deg, similar to the engine sump. Front diff about 45 , back diff about 55, all wheel hubs about 40-45 deg. the ambient was 25 degrees.
Typical cruising at 110 ks, about 12 psi boost, 400 deg C exh temp, going up a hill the exhaust can get up to 600 deg, but not usually for long. at 100 ks and below the exh temp is usually in the 300 to 350 deg range
I did some slippery offroading but used the difflock, and didn't get a chance to try out the ashcroft ATB in the center diff..
We found some accommodation at HB, and did whale watching which was good, and fed the dolphins at Tin can bay on the way back. TCB to Pamona via the Coloola way, it was pretty rocky and rough in places. Kin Kin to Pamona was very pretty. cheers simmo