Thread: Discovery 2 LT230T rebuild story

Originally Posted by eckolsim

Last New Years I took my disco for a trip out west after rebuilding the head for a test run.
as the car had been mothballed for a while with a few items worked on over the last few months I was hoping that this run would bed the car back in and confirm the head was good.

For background I had the auto rebuilt due to the torque converter dying, in the process I started chasing the heavy clunking in the drive train. By the end of the exercise the rear diff and transfer case were also built. For these items I decided the work was above my skill level so entrusted the work to some local recommended workshops.

The auto I am absolutely pleased with. Minor pickup on the install as I found out later. Apparently they too found the top starter nut hard to fit and chose not to......

The rear differential has been OK also. Happy days..
Now for the transfer case. After about 4-5k km I started to get a leak. Nothing serious. Kept looking and couldn't find it.

Back to to the New Years drive, somewhere between Yass and Young I had a major transfer case fluid loss. Couldn't tell how much due to rain but could smell it. I didn't have tools to check the fluid levels while always so kept checking the leak. It had stopped. So drove home to Sydney.

What do they say again, if it ain't leaking then it's out of oil......
Yep. Hit Richmond and started to hear crunching. Called the NRMA but had no joy. They didn't have a flat bed that could carry myself and the kids. Bugger. Nursed it home.

Transfer case strip report:
1. Transfer case had 30ml of oil on arrival.
2. Lower rear output case had lost a bolt causing the fluid loss. (On the counterweight)
3. Output diff gear lock nut chewed.
4. Centre diff had loose bolts.
5. Mount bolts to transmission finger tight only.
6. Bolts that were tight required 1/2" breaker bar to undo. 50% bolt heads damaged. Had to get nasty with some bolts as I split a socket! (read grinder with cutting wheel).
7. Missing bolts from transfer case and transmission mounts.
8. Internal gears ok I hope. Well no visible damage.. Bearings cooked.

Says a lot for workmanship these days.

Now for the good news. I ordered a rebuild kit from Ashcroft. To my door in 4 days for $250. Full comprehensive kit. Awesome. As for the bolts, sourcing flange bolts is a nightmare. I located a US supplier who had all of the weird sizes required and just received the shipment. Am replacing most bolts due to head damage and stretching. Very professional service.

Shout out to BelMetric Automotive in the US. Atlas was the OEM but are now gone. Metric Hardware, Metric Fasteners, Metric Bolts, Metric Nuts & Time-Sert Thread Repair

Just about to put the case back together now. Most grateful to YouTube for the tutorials especially the Bearmach sponsored Land Rover tutorials. A transfer case rebuild now doesn't seem that hard.

The proof will be in the end testing I expect. Will advise.

simon

Wow, that's bloody nasty but it's great and extremely satisfying that you've learned new skills.
I tend to think most of us have similar stories to tell.

Yes, Ashcroft's are great to deal with, extremely timely service, quality gear and I've had Dave Ashcroft return a query within minutes!
FWIW I've had a similar experience with Turner Engineering in the UK.
Frida Turner returned an email on Boxing Day once!!

Did you try a warranty claim?

Lemo, the warranty was for 6 months or 10,000 km. Will talk to them but don’t expect much. Just grateful that there doesn’t appear to be any damage. Hope the gears aren’t heat affected.

Note that the work was done 18 months ago and the car had only done 5,000 kms since the work (mainly short trips).

Tough one Simon,

you're right the LT230 can be rebuilt at home if you take your time.

But quality workmanship is hard to find these days, ( at any price).
when I changed by transfer case to a disco 2 one I found my R-380 gearbox vent has not been connected to the gearbox, for 15 years. Its in a difficult to access place . ( GB was changed under warranty for the 1st owner at LR dealer)

New front drive shaft fitted, missing grease nipples and not greased. (highly regraded Land Rover workshop)

Tdi-300 ; New cam belt, & tensioner etc fitted, ( not the crankshaft pulley as requested in writing before the start of the job), 2000 km later the engine is wrecked, ( after 200,000 kms of trouble free motoring). The cam belt broke because the spot welded flange came off the crank pulley, a problem well known about at that time, and easily fixed by using the forged crank pulley with integral flange. ( another highly regarded land rover work shop).


My rebuilt TC is still running sweetly after 10,000 kms, when you go on a highway run if you can carry an infra red temperature gun, its handy, coast to stop on the side of the highway, or when you pull into the roadhouse. My TC runs at about 65-70 deg C, ( ambient plus 35-40 deg), at high way cruising speed. (difs about 45-55 degrees, wheel hubs about 45 -50 degrees).

when refitting it we found easy to have the back wheels on a set of ramps, and jack the body up a but, it makes the TC horizontal so it can be rolled into position on a trolley jack.

If you take your time and follow the book it should all come out well, good luck.

cheers
Simmo

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