whats the differende between a defender R380 gearbox and a disco one

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This is still an ongoing project. I want to take the selector remote off my box and the quadrant to get some proper measurements, in order to get the selector quadrant really tight on the shaft, nothing worse then a poorly fitting shaft!
 
has anyone got any pictures of where the gear stick sits with the disco box in a defender?
 
This may help illustrate to everyone what is involved in converting a disco gearbox to fit a defender, its really easy, just time consuming to ensure a tight fit and accurate alignment.

I cut off the rear part of the discovery selector to retain the part that fits onto the shaft, then just welded a bit of 17mm bar on the back, a hand filed it go get a tight fit with the defender selector yoke. I also spotted through with a drill to ensure positive location for the retaining screw so the yoke can't rotate.

To be honest to do a professional job I would use a lathe and turn down an extension, but as I don't have one I had to make do with what I had. Selects all gear easily and no play in it.

To give an idea of the length of extension required from the centre of the screw on the existing selector shaft to the centre of the selector quadrant is about an inch.

A couple of photos to illustrate.

P1020488.jpg


P1020489.jpg
 
personnaly i just change the shaft ,about an hours work ,but with out the tools not easy for everybody ,certainely ingenious and cheap ,lt77 top can be used if you remove the interlock bolted to the underneath and reverse plunger
 
Personally I'd just change the shaft as well, but without the appropriate tools I'd have to pay someone to do the work.

As its an unknown box bought in good faith I wanted to keep things cheap. if it is knackered I'll just rebuild my defender one.
 
I was a little concerned about welding to a forging, but even with it tacked on it was rock solid, there is a lot more weld underneath where the forging spreads out. With the heat turned up there is no way that is going anywhere.
 
minimole23 said:
I was a little concerned about welding to a forging, but even with it tacked on it was rock solid, there is a lot more weld underneath where the forging spreads out. With the heat turned up there is no way that is going anywhere.
Click to expand...

Very good read, agreed.
Mole, why the concern about welding to a forging, mate ?
 
Ninja Haggis said:
Very good read, agreed.
Mole, why the concern about welding to a forging, mate ?
Click to expand...

Given the difference in materials and grain structures, I wasn't sure how well they would stick together. I have no concern now but until you try it you never know. I don't want to be worrying whether the extension will break off, come loose or generally move in any way. I like doing things once and once only.
 
minimole23 said:
If mine works I may be able to knock a few out for the benefit of others.

Just need to get a disco box now to experiment on.
Click to expand...

hi minimole have you decided if you will make them to sell to others? i have a 300tdi 90 and lost all gears whilst on motorway been told that it is most likely the input shaft worn.
i cant afford a recon but local tat yards have plenty of discos knocking about so if you would make and sell me an adapter i would :dance:
cheers Buck
 
I knocked up the extension from a combination of the old disco box and a bit of steel bar, as I didn't have access to a lathe to do it properly.

As detailed on the previous page, its an easy thing to do.
 
jamesmartin said:
personnaly i just change the shaft ,about an hours work ,but with out the tools not easy for everybody ,certainely ingenious and cheap ,lt77 top can be used if you remove the interlock bolted to the underneath and reverse plunger
Click to expand...


Sorry to resurrect an old thread but i'm wondering whats difficult about swapping the selector shafts, what special tools are needed?

i want to convert a LT77 disco box for use in defender (i have moved 200tdi engine moved forwards) so wondering if its possible to do the shaft swap yourself or if i would have to cut and shut the defender/disco shafts.
Ad
 
removing seal collar ,5th gear selector hub and layshaft gear ,defender shaft is longer as disco uses a yoke and defender uses quadrant ,conversion piece seems a good way to fit disco box in a defender
 
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