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Thread: D2 Transfer Case tear down - problems found

  1. #1
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    D2 Transfer Case tear down - problems found

    Hi all,
    I have the Transfer Case out of my D2 to put an overhaul kit through it.
    However, on opening the diff assembly we find that 2 of the 4 spider gear copper shims have been worn completely away and the gears have begun to wear away the casing.
    Question ~ does this mean that the casing is destined for the metal bin OR can we still use the casing, and install a Differential Gears Kit, and double shim to make up for the 2 worn sections?
    IMG_7964.jpg
    IMG_7965.jpg
    LROCV member #131
    1999 build D2 TD5 Auto, Mantec snorkel, 2" LRA spring lift, ARB on board air, Ashcroft ATB, CMM air ram CDL shifter, swag & gold pans ....

  2. #2
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    That's a really common problem with the such diff.

    Can you budget for an Ashcroft ATB to replace the open diff?

    That fixes all your issues.

  3. #3
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    Quote Originally Posted by rick130 View Post
    That's a really common problem with the such diff.

    Can you budget for an Ashcroft ATB to replace the open diff?

    That fixes all your issues.
    What's an ATB?
    LROCV member #131
    1999 build D2 TD5 Auto, Mantec snorkel, 2" LRA spring lift, ARB on board air, Ashcroft ATB, CMM air ram CDL shifter, swag & gold pans ....

  4. #4
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    Ashcroft Transmissions

    Replaces the open diff.
    It's a torque biasing centre diff, a gear type limited slip diff that you can still lock when needed.
    It reduces the backlash from centre diff wear and improves driveability on dirt and in the wet in my experience in a Defender.

    I have another one here to fit to my D2.

  5. #5
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    I Have a D2 transfer case for sale. i believe it is in good condition.

    Ian
    Bittern

  6. #6
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    D2 Transfer Case tear down - problems found

    Quote Originally Posted by ian4002000 View Post
    I Have a D2 transfer case for sale. i believe it is in good condition.

    Ian
    Bittern
    Thank you Ian, but a recently purchased LT230T has turned out to be in a much worse condition than my original when we opened it up, ….so I’m a bit “gun shy” re trying my luck a second time around on a used TC D2 Transfer Case tear down - problems found
    LROCV member #131
    1999 build D2 TD5 Auto, Mantec snorkel, 2" LRA spring lift, ARB on board air, Ashcroft ATB, CMM air ram CDL shifter, swag & gold pans ....

  7. #7
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    Many years ago, about 30 to be exact, I bought a 77 with a very sloppy LT95.

    I took it to an Indie named AFAIR Land and Sea which was at Sylvania in Sydney.

    They actually machined the star gears and diff case in the LT95 and fitted oversize bronze bushes , which tightened up the transfer greatly. ( along with I imagine new thrust washers etc.)

    I would think that this would be possible with an LT230 , but I don't know if anyone does it these days.
    Regards PhilipA

  8. #8
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    I’m with Rick on this
    The LT230 is about the dumbest simplest bag of gears possible - it’s only weakness is the diff and running a layshaft into an al housing

    I wouldn’t even muck around with the diff just put in an ATB and while the box is on the bench machine the case and sleeve the layshaft / seal mount

    Put it back together and forget about it

    S

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    Quote Originally Posted by roverrescue View Post
    I’m with Rick on this
    The LT230 is about the dumbest simplest bag of gears possible - it’s only weakness is the diff and running a layshaft into an al housing

    I wouldn’t even muck around with the diff just put in an ATB and while the box is on the bench machine the case and sleeve the layshaft / seal mount

    Put it back together and forget about it

    S
    I’m doing the math at the moment …… for a plan A and a plan B….. more laterD2 Transfer Case tear down - problems found

    BTW i did find some helpful info from a 2011 thread in Technical Chatter on rebuilding a LT95
    LROCV member #131
    1999 build D2 TD5 Auto, Mantec snorkel, 2" LRA spring lift, ARB on board air, Ashcroft ATB, CMM air ram CDL shifter, swag & gold pans ....

  10. #10
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    Quote Originally Posted by onebob View Post
    I’m doing the math at the moment …… for a plan A and a plan B….. more laterD2 Transfer Case tear down - problems found

    BTW i did find some helpful info from a 2011 thread in Technical Chatter on rebuilding a LT95
    And you would love the ATB. I have a pair of very similar Trutracs on my wee beastie and they really do transform the car. I even like the stronger self centering on the front diff, as well as the "lazy" approach you can usually take off road or on marbles.
    MY16 D4 TDV6 - with a little Cambo magic for towing "The Brick"
    MY95 RRC LSE Vogue Softdash "Bessie" (turning circle comparable to QE II) with MY99 TD5 and 4HP24 transplants. Back home Nov 22 after a magic overhaul by Chivalry
    SADLY SOLD MY04 D2a TD5 auto Classic and MY10 D4 2.7 both with lots of goodies

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