Changing the gear ratios in Defender transfer box

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Just get a second hand box with he right ratios, to buy the gears separately is expensive and you still have to fit them. You would need to remove the box
 
Yup, it's a box out job. The transfer box is quite a nice one to work on if you like rebuilding gearboxes or are beginner in those dark arts. Yes of course you may be able to get a secondhand Discovery box cheaper, but with new gears and bearings at least you know you've got what amounts to a new box. After all, there's usually a reason why the Discovery gearbox was taken out in the first place!
 
Kwakerman said:
You almost answered your own question, its a Discovery and probably rusted away!:D Like the old saying goes, 'Land Rover only built the Discovery so that the Defender would have plenty of spare parts in the future' :D:D
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Was going to say the same thing :D. The usual reason for removal is there is no discovery left to bolt it to!
 
Thanks for the replies, I suppose I could check/rebuilt a Discovery one then I always have the original to go back in. I take it the boxes are the same and are essential a straight swap.
 
I think I am right in saying there is quite a comprehensive video of how to change the gear ratio's on Ashcrofts website.
 
Make sure you get the input gear if you buy another TBox.
Handbrake mechanism is different from LR to disco but you can swap over.(think you have to drill/tap 4 holes)
Just changed mine from a 1.44 to 1.22 .1st is a bit longer & need a bit more gas to pull off. Once going it's all fine, 5th cruises
Only problem I found was reverse was a bit too high. Struggled off road on a reverse hill but I had low box.
I run 750s which is a bit of a push on this box.

If your good with spanners less than a day to fit. Need a jack or crane to lift TBox.
 
Hicap phill said:
If your good with spanners less than a day to fit. Need a jack or crane to lift TBox.
Click to expand...

Can be swapped in an afternoon if everything comes of easily, but can take a whole weekend if it puts up a fight! You can use the discovery handbrake bracket, and it actually makes it easier to get a spanner onto the cable to adjust it.
If you are feeling strong you also do not need a crane. you lie underneath it and lower it onto you chest bench press style, with the reverse to fit while a helper on top lines everything up. Save lots and lots of time doing it this way but they are not light. I would not jack it unless you have a cradle to rest it in and even then it might be a challenge unless it is a custom one for the transfer box. They are not a sensible shape and tend to tr and twist and roll so you end up lifting it to keep it in line anyway hence doing away with the jack and just lifting form the beginning!
 
Easiest way to re fit is to slide transfer box along 2 lengths of threaded bar approx 200mm long fitted in place of 2 bolts, it serves as a guide and saves the weight of the box resting on the oil seal and causing a leak further down the line. Once back on remove threaded bar and fit bolts.
 
Even with an apparently functional secondhand box I'd want to have a look inside to see the condition of the gears and see how the bearings were doing. You might as well make sure everything is as fresh as it can be while the box is on the bench and easy to work on.
 
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