Disco II - Transfer Box Linkage Broken..!

GPHDISCO2 · Feb 24, 2018

Help! Last night the high and low range transfer box gave up the ghost on my 2003 Manual TD5. Managed to limp home with the diff. locked. Did some exploring this morning, removed centre consul, drilled the pop rivets from gear access panel and found that transfer box linkage mounting has snapped. See pic's attached. Can this part be replaced? If so what's it called and where can I get one?

goonarmy · Feb 24, 2018

Put this is the disco section for some advice

discool · Feb 24, 2018

I cant see any thing broken in the three photos.

Look for the part your self in this link.
http://www.allbrit.de/select.cfm?PAGE=Q01&CAR=L5&SPRACHE=EN

GPHDISCO2 · Feb 24, 2018

It's the metal bracket that's broken, it's snapped just at the "H" in the L-N-H emboss. See pic 4312. Think I may have sorted bracket and cable. Box though must be pretty stuff if it caused this to break. Any advice on how to loosen it up while i have cables etc of. Also how do cables come of, there is a clamp which i can release, do they screw out?

Thanks

G

Hellastony · Feb 24, 2018

To remove the linkage. First there is a clip on the clevis pin that holds the end of the cable into the U lever on the end of the cable where it connects to the T box. This clip just lifts up and away from the pin. Remove the pin so the end of the cable is now free. With two spanners undo the adjuster nuts that are either side of the broken bracket, ease them over the cable as you pull it out and then it should be free of the broken bracket and the T box

Tony.

GPHDISCO2 · Feb 24, 2018

Perfect thanks Tony. Got that part sorted. Any ideas about how to loosen up the shift in the box itself?

discool · Feb 24, 2018

I can see clearly now, now I know where to look.

Hellastony · Feb 24, 2018

They do stiffen up through lack of use. I can only suggest trying to move it back and forth by hand somehow from the top, probably best done whilst the oil is hot, and the engine is running, gear in neutral. I am surprised that the force has broken the bracket, but I suppose it is possible that there is a significant problem within the T box that is stopping it moving at all, and no amount of pushing/pulling will solve. If that it the case the T box will have to come out anyway, but I would try moving the lever first if at all possible. Has it been able to easily select high/low recently before the problem started?

Tony

GPHDISCO2 · Feb 25, 2018

Hi Tony, prior to break, some issues with it slipping from high into neutral after I used low range for the first time this year with the snow over Christmas. Had been fine up until fail so did as you suggested, good news is TBOX seems to be working as it should, shifting easily (I slipped a short metal tube over the lever) and moved back and forth - fault must have been with failing bracket. Have sourced a replacement, should have it Wednesday and will fit next weekend. Have loosened all th bolts bar the one holding cable - bugger to get at, any ideas? In the pick it's of the car - drivers footwell in the way on mine. Thanks again.

GPHDISCO2 · Feb 25, 2018

Go it, WD40, and short flat 10mm socket. Just to re-fit now. Will let yo know how i got on and will add pics.

G

MJI · Feb 25, 2018

I had to lubricate my lever lock unlock cable would not move, mechanism had seized, lots of movement and lubrication fixed it

Hellastony · Feb 26, 2018

GPHDISCO2 said:
Go it, WD40, and short flat 10mm socket. Just to re-fit now. Will let yo know how i got on and will add pics.

G

Great news, well done. In view of what you said about it dropping out of high, when you replace the cable make sure it is adjusted so that it fully engages in high and low to stop this.

Tony

GPHDISCO2 · Mar 2, 2018

Thanks Tony, snow has impeded progress, part has not yet arrived, Couldn't resist taking it out last night, we have about 4inches of snow here and a pretty steep lane. Used the end of a small garden fork to shift the T-Box MacGyver style, great fun and Disco handled conditions brilliantly, even though it was baltic with cab exposed to elements through centre consul. Thanks for the tip re. adjustment. G

Disco II - Transfer Box Linkage Broken..!

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