Thread: Disco Transfer case into Defender

Apart from the disco being 1.22/1 and deefer 1.4/1 it will work fine.

As above. Shafts all straight on.
You will probably have to swap a speedo encoder out for the Defer cable drive.- 5 minutes off the car.

You will need to use the defender transfer shift linkages

Thanks All for the prompt replies and info, much obliged, Regards frank.

Hi guys I was researching in the aulro about this, and have a question.

The disco TC rebuild for putting in my 95 defender 110 tdi is going fine, but the front drive flange on the disco TC is 110 mm diameter where as a defender drive flange is only 95 mm.
The defender drive flange won't fit on because it uses the course splines as opposed to the disco shafts have a very fine spline arrangement, for the drive flange.

its only a problem on the front output, on the rear I have a complete defender out put housing, shaft and flanges etc to put in from another TC.

Ashcroft ATB and extended sump going on.

thanks if you can offer any advice cheers simmo

just to compound the flange issue.

some flanges are a different PCD on the mounting bolts, you'll need to swap them over. I think from memory that its a variation between years and disco/deefer. I've only been caught out by it once.

every other time its been a case of swapping the flanges and they slide right on, in the one case the PCD was wrong so we went to change flanges over and then found the spline count was wrong.

Hi Guys, the input shaft is shimmed beautifully, the output housing shim is a touch big. I think its a bit tight, so I'll rub the shim down a thou with some wet and dry paper.
The hi lo range selector works smoothly until I tighten the plug in the last 1.5 turns and it binds up the selector shaft. Has anyone else had this problem?
The ball looks the right size, the spring looks Ok it looks like the plug just goes too deep into the hole.
The difflock selector works smoothly as well with a nice detent feel. I kept the two detent components completely separate during the rebuild.

cheers simmo

Simmo,


I have a d2 box here with the large front and small rear flanges.
Appears to be fine spline.
If the flanges are interchangeable f/r, you can borrow this one to get you going.


Cheers,
Tony