Disco 1 Fitting a Disco 2 TD5 front propshaft to a Disco 200Tdi

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Gandalf The Grey

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Sturmer, Haverhill, Suffolk
I need some advice if possible please.

I needed to replace my Disco 200 Tdi front prop and had read and heard that some folk had replaced it with a D2 Td5 front prop.

Well, I went ahead and bought a new D2 Td5 front prop and when coming to install it, I find that the flange on the diff is too small compared to the mating face on the propshaft.

I then went and ordered (what I thought was the correct flange) Part No STC4858 and now find that this one will not fit in the diff nor is it big enough to fit to the propshaft.

Any suggestions on which flange will fit a 200Tdi front diff and will be the right fit for the prop or have I wasted my money and time?
 
Discool, that is the same flange that I bought and doesn't fit.
There was no spacer.
Must mention that my Disco is a 93 model.
The "shiny" part that goes into the diff is longer than the flange I removed, so sits proud of the diff and as mentioned. That flange is also the same diameter as the existing one, so too small to fit the prop
 
I don't know but I'm taking it as the original spacer remains, if so then installing the new flange with its attached spacer will leave the flange sitting proud, as for the flange size, I don't know, how is it retained to the pinion? castle/ locking nut or the single screw what ever size that is which is used on both my diffs.

An expensive exercise if as u say the prop is new :(
 
The flange on the left is the original flange removed from the front diff. The one on the right is the one I bought.
_MG_4061.jpg


the next two photos show how much smaller the flanges are compared to size of the propshaft
_MG_4062.jpg


_MG_4063.jpg


The original flange is held in with a castellated nut.
Hope this makes a bit more sense now :)
 
I have heard of a few people fitting TD5 props to Tdi diffs, so it must be possible .. wouldn't you be better either getting a TD5 diff flange? Maybe have a chat with whoever sold you the prop, they ought to know .. ;)
 
Interestingly, just found out that the prop is not fitted with the sliding end toward the trfr box, as on the D1.

So now need to find a flange to fit the transfer box instead.

Another problem I have, is that I cannot find the part number for the diff flange on a 93 200Tdi, as the online Microcat only shows the later flange, which is the one I have.
 
Yes your correct LT230 and the collar is discribed as a mud shield, it was available as a separate item and still maybe, but it now appears to be fitted to the flange, as both of them are on my diff pinion flanges front and rear ie. late 300 series.
 
Last edited:
Gandalf The Grey said:
Eventually found what appears to be the correct one https://www.lrdirect.com/FRC3002-supplied-by-allmakes-branded-allmakes.html
it is without the collar.
Thanks for trying Discool, it is much appreciated.

Am I correct in assuming the D2 also used the LT230 transfer box?
If so, my search for a flange may not be too difficult.
Will keep you guys informed.
Click to expand...
its the transfer box front flange you change not diff ,whichever diff flange you buy they all have the same pcd
 
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