Transfer box maintenance

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5tox

Active Member
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I'll soon be replacing the transfer box on my 90 as i believe the rear bearing has gone, the reason i think this is that i get a squeeling noise when under load (a bit like a slipping fan belt)
With the centre of the seat box open, my brother noticed that the sound was coming from the handbrake drum, with the handbrake completely disconnected i'm still getting the noise when under load and when i go down through the gears.

I have been told that a 300TDI disco box will make it better on the road due to taller gears and the input shaft should be better due to cross drillings.

I have a few Q's before i begin, is the input shaft lubricated by the T/X box gear oil or should i liberally apply grease before sliding it onto the gearbox?

i know that the LT77 gearbox has an oil filter, does the transfer box?

Is there anything else i should do to the transfer box while its on the floor before fitting?

Many thanks
 
all the t/boxs built since the late 90s have cross drilled gears,its the cross drilling that lubricates the gear box out put splines, theres no filter in t/box,youd need to swap the speedo drive gear for your old one , plus your old hand brake assembly, which if not direct cable type will need 2x 8mm holes tapping in rear housing
 
Yesterday i picked up my 300TDI transfer box which i'm hoping to fit to my 90 tomorrow, should i swap over the hand brake drum or keep the disco one?
If i swap them over ill need to drill and tap some holes for the linkage but if i can get away with it i'd like to keep the discovery drum... any idea if it can be used? can i just replace the cable to suit a defender?
 
Thank you much appreciated! i'll just drill and tap the holes as its all cleaned up and ready to be fitted.
 
If you plan on using the discovery 300tdi handbrake, bear in mind that you'll also need to buy a 300tdi defender lever. Don't ask me how I know :rolleyes:
 
Thanks for all of the kind advice, today i got the 300tdi transfer box fitted using the old defender handbrake setup, only had to drill and tap 2 holes as the other 2 were already there... nice and simple.
The only problem i found was that i don't have a mechanical speedo drive / gear to suit my new box, it was electronic.

What do you think the chances are of finding somebody on here with a knackered 200TDI transfer box who would sell me the speedo drive gear?
 
Last edited:
5tox said:
Thanks for all of the kind advice, today i got the 300tdi transfer box fitted using the old defender handbrake setup, only had to drill and tap 2 holes as the other 2 were already there... nice and simple.
The only problem i found was that i don't have a mechanical speedo drive / gear to suit my new box, it was electronic.

What do you think the chances are of finding somebody on here with a knackered 200TDI transfer box who would sell me the speedo drive gear?
Click to expand...
You can buy the gears (different ratios available to suit your tyre size) and about £12 but there should be one in there anyway for the transducer, you will also need the clamp / stud and nut to hold the drive cable in. Cant imagine they would be more than a couple of quid.
 
Like I said yours should have one already as it is used to drive the electronic transducer. If you remove it (one bolt) you should see a small square drive hole about 3mm square, this is the end of the gear that the cable would then slide in. All you should need is the clamp parts to hold the cable in place. One you get it sorted if the speedo is reading out then you may need to change the gear to one with a different number of teeth (and different colour) to match your tyre size.
 
Also, it's worth having a fiddle to make sure the female bit in the housing is properly engaged with the male bit on the cable or transducer. In my recent transfer case rebuild I spend a while troubleshooting a non working speedo and discovered that my transducer wasn't fully engaged with the square hole in the speedo drive. The male part was a tiny bit too fat, so I filed it to fit, and now it is all working.
 
Thanks for the replies, i have ordered the blue 20 tooth gear which should slide into my existing housing, i'll take a look when it arrives and see if it all goes together.
From the searches i have done online i should be ok now..... fingers crossed.
 
Popped home over lunch and my new gear has arrived, the actual coloured gear itself is plastic though, is this normal?
Surely it will wear out in no time?
 
just swapped them over and the original is also plastic so no problems there, according to the sat-nav my speedo is reading about 4-5mph too quick which i can live with, bearing in mind that my current tyres are 7.50's, ill soon be swapping to 235/75/16s so hopefully that will help correct it
 
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