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I answered this a day or two ago but it seems not to have posted, so I'll try and remember what I said.
I see the complete gear set is STC2940 and is available from several suppliers. It says 83-06 and 07 on, so that's pretty much all of them. For £50 or so I'd get one of these because chances are it will fit inside the casing. Yes, maybe there are a few knocking around with different numbers of teeth but provided you replace the lot as a matched set, it should all work.
When the TD5 came along the design of the diff casing changed and the splines where the transfer box gears fit were different. As you'll have seen from taking it apart, the diff casing also serves as the shaft for the final drive gears in the transfer box. So the outside of the casing changed, but (and what's crucial here) the space for the innards remains the same.
My old one is now doing duty in another gearbox so is already spoken for, as it were. Sorry!
I see the complete gear set is STC2940 and is available from several suppliers. It says 83-06 and 07 on, so that's pretty much all of them. For £50 or so I'd get one of these because chances are it will fit inside the casing. Yes, maybe there are a few knocking around with different numbers of teeth but provided you replace the lot as a matched set, it should all work.
When the TD5 came along the design of the diff casing changed and the splines where the transfer box gears fit were different. As you'll have seen from taking it apart, the diff casing also serves as the shaft for the final drive gears in the transfer box. So the outside of the casing changed, but (and what's crucial here) the space for the innards remains the same.
My old one is now doing duty in another gearbox so is already spoken for, as it were. Sorry!