Disco 1 Transfer box input gear wrong?

Hi guys. We’ve just changed a transfer box on my mates 300tdi D1 from a 1.2 to a 1.4 for better gearing on larger tires.

The 1.4 box we used came from a TD5 90 a little while ago, but the input gear was always bagged separate from the box. (Was told it was the original though)

We have put the box in, and put the input gear in, but are unable to get the PTO cover on as the gear looks a little too big. I’m pretty sure this is the original gear from the box but maybe it’s been swapped at some point as it just won’t go in.

Here is a picture of the gear from the 1.4 (cross drilled) next to the 1.2 and it’s slightly bigger as can be seen.

I feel there’s something stupid we’re missing here, because my understanding was the boxes should both be comparable with R380 on the Disco?

Is the gear shimmed?

I thought the gears were different?

The bearing race is shimmed on the end plate, yes. But it’s the original end plate/pto cover. And this should be the original gear too, so it should be shimmed to match. The end plate sits about 2/3mm proud, more than a shim’s worth anyway.

The gears are different between the 1.2 and 1.4, but I knew that was the case.

I just can’t fathom how the gear won’t fit properly when it’s meshing right in the txb.

did you get another end plate/pto cover with the gear, maybe the differance is made uo by a deeper cover plate

I was looking a this, item No 9, housing bearing shaft have you got this item, as it looks like a spacer

https://allbrit.de/epc.cfm?PAGE=Q01045&CAR=L5&SPRACHE=EN#8

frostythor said:

did you get another end plate/pto cover with the gear, maybe the differance is made uo by a deeper cover plate

I was looking a this, item No 9, housing bearing shaft have you got this item, as it looks like a spacer

https://allbrit.de/epc.cfm?PAGE=Q01045&CAR=L5&SPRACHE=EN#8

Click to expand...

Thanks for the reply.

Yes that looks like the rear bearing housing, we have this.

However, I’ve since learned that there are two types of housings, numbers FTC4866, and FRC6943. We have the latter of the two, but FTC4866 is thicker, and my theory is that the input gear is correct (as it meshes in the box perfectly), however I think the cover has been swapped by mistake at some point.

So I’m currently on the case (pun intended!) to get hold of an FTC4866 to test my theory.