Thread: Disco Transfer case into Defender

Several years ago I bought a transfer box that was supposedly pulled out of a Disco to put in my Defender 130 with 300Tdi. Would be overall more suitable to have a slightly faster high range when used mainly in flat country. However pulling off bottom plate to check condition inside revealed that it was the !.003:1 high range type. Bits attached to it and the serial number indicated it was originally in a mid '80's Rangie with Torque Flite auto.


Installing this box as is into a Defender would result in having first and reverse gears in high range too fast. Anyway, I did some looking, thinking, measuring and calculating. Then got a 22 tooth top shaft gear designed and cut to mesh with the 44 tooth high range gear on the intermediate cluster. Instead of the standard 26 tooth top shaft gear driving the 41 tooth middle gear on the cluster. Layout is something like in Series transfer box but back to front. Overall ratios 1.27: 1 High range and 4.21:1 in low instead of the standard 3.32:1. The latter rather similar to the Maxidrive 30% slower low which whines due to straight cut gears. My modified box still whines at high speed in both high and low after 10, 000 km. Maybe unlikely to wear in and quieten itself much more but I still like it with faster high and slower low ranges than standard.


Would be interested to hear if anyone else has ever done this modification, which basically only uses one part, the new top shaft gear that is nothing like anything ever supplied by Land Rover. Meanwhile, a similar result could be obtained using a 1.003 high range transfer box as is and installing (standard Series) 4.7 crown wheel and pinions in diffs or the stronger aftermarket 4.75 ones. Would give overall about 1.33 high and 4.45 low.

Thanks for your advice, about 2 turns out was spot on, nice feel.
I checked my other transfer case and has a flanged cap. So i fitted them but the feel is the same as when the screws are in and backed off a couple of turns. comparison phot0 below.
That would explain why the hi lo dog clutch looks like it was never engaged, it was probably jammed since the last overhaul.

I used locktite hydraulic sealant , its good stuff it locks the thread and acts as a sealant as well.

The drive flanges are a challenge I have three different sized disco ones. the ones with the same PCD have a male spigot the defender one has a female.

I might just buy two new TC defender output shafts and put them in that way defender flanges will fit. I have a new ashcroft ATB inside so i don't want to put too worn parts against it. My other spare transfer case is from a defender but looks very neglected the oil was filthy brown and the potential donor shaft splines where they fit in the diff center are showing signs of abrasive wear. I cant figure that one out, why let a $2000 transmission be damaged just for the want of $15 worth of oil? .

The input shaft shim is 3.32, was supplied by MR automotive.

I sanded down the output housings /diff shim to 2.35 mm and it feels good. I warmed up the housing with the heat gun to fit the shim and bearing race. I could feel the bearing getting firmer, ( more preload), as the front housing cooled.
My guess is the preload we put on the tapered roller bearings is mostly gone when the TC is heated up to 80 or 90 c during operation.


I have the speedo drive small gear , but still chasing the carrier it spins in and the thing the cable connects to. I'm not in a hurry so things will come together eventually. thanks

cheers simmo

cthanks again for your advice cheers simmo.

the drive flanges

cheers simmo

The defender flanges on my 95 defender are big splines, you can see the rear drive flange I changed out a few months ago.

The drive flanges on the disco-2 TC are fine splines, you can see the drive shafts and the drive flange. Is that usual they're completely different?

Did some defenders come with the fine spline drive flanges?, that would be the best solution?

Other wise what to do? A set of defender drive shafts is over $400.

The disco 2 bracket for hi low selection and the TC wiring loom is still looking for a good home for free

thanks if you have any advice.

cheers simmo