lol im saving gearboxes to trade in .....

I've just been given an LT95 for the cost of a pint :D so that's my spare sorted!


DD281D24-C44E-4AB9-97ED-7B25F766892D-757-000001346A8C8D57_zps65f4b96e.jpg



Will look into getting a roverdrive for it at some point too

had this with our old mk3 transit it had the old type 9 box,used to eat reverse gear could not get one they were like rocking horse ****e,in the end utilised a mt75 later box by cutting and plating the cab floor,but in the transit it was just tidy up with a newer gaiter,also took a type 9 out of a sierra and put the transit linkage onto that,PITA as well and reverse gear still jumped out after a bit


Always fun making stuff fit ;)
 
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Right here's the accurate measurements and some pics


Its 43.5mm tall

5/8th shaft is 20mm long from and then a tapered mound below that or 3.3mm

The base is then 18.2mm tall

The hole in the centre of the base is 5/8th's or 15.87mm by 17.1mm deep

The two M10 x 1.5 grub screw holes are 4.1mm off the bottom of the base and then the hole on the shaft is 5mm from the top, these measurements are on the tap size and from the outermost edge of the hole not the centre.

The holes are offset at 65* from each other, should add that the hole on the shaft is not all the way through it is about 5mm deep and only has one turn of the tap due to the grub screw that fits in there having a tapered bottom

Width of the fat part is whatever you want it to be, I'd suggest 1 1/4" as it looks about right to me

You'll need to buy one grub screw as you can reuse the one from the disco box for the second

Heres the pics of how to do it anyway

0DD18F8D-226D-45DF-8B64-3388FD89B151-1909-00000384EBB90191_zps47f8caf1.jpg


Long bolt is from this hole

102B5E70-FA57-4B0B-B4A9-2381DD52CD2C-1909-00000384FDF8082A_zpse94345ed.jpg



Short bolt holes

86791A90-3585-4651-BCBA-740F484CA849-1909-000003851EA17F89_zpsfca6e940.jpg


10BDC78C-DDCC-4AA4-85A3-80E3404D5858-1909-00000385576BC25B_zpsd6406e24.jpg



331647BA-9BD7-400E-B34D-92317F941746-1909-000003858BEC354D_zps8db1ff7d.jpg


With those three removed then take off the cover plate to get access to number four


85C0316D-A899-46E7-976D-4B4219AEC7B7-1909-00000385BA21C7B6_zps80c4474f.jpg


7A6CEF4B-6D9C-4A28-9165-C2B5CF669E99-1909-0000038661579348_zps8d3d0dbc.jpg



Remove the selector housing


E2469980-AE2B-40C3-9566-B0527A5F5F2E-1909-00000386840F6340_zps2e6e5fdf.jpg




Selector shaft exposed

766FAF3F-0941-4270-8B75-B598E784E532-1909-000003869CABB31E_zps85267482.jpg


64AEA3F7-F935-4C47-B27E-C21370729D37-1909-00000386C662307A_zpsb4bff60d.jpg



5mm allen key and a suitable driver to get some purchase on there

69A30FA1-7F12-426A-B97A-F7EAAF056E75-1909-00000386ED628497_zps80a1a2ce.jpg



Remove the screw


3C589B5C-BD1A-499B-ACAF-055EEFF73D10-1909-000003870937BFF5_zps912588e1.jpg



Other grub screw you'll need


5F0172EB-9BE8-4434-9B01-79D1EC4A37A1-1909-0000038729269212_zps60a05f7e.jpg



This is the selector rail adaptor


D3DB6449-D294-46A3-9192-B256180D348A-1909-000003874602D14B_zps253033c9.jpg



Gear selector quadrant

85EC455A-7F8A-49FE-AEB0-A5A14FF4EAD3-1909-0000038762933330_zps3fdbda15.jpg



You need to push the shaft into third in order to get enough space to remove the disco selector and get the defender selector mechanism on there

268F106F-FAEE-424E-94E8-75F02505775B-1909-0000038777AB3DE6_zpscfb5cdfe.jpg




This is the old mechanism


738549A7-B1B1-4544-8DE1-83C5016F8766-1909-000003879335874A_zps178a9a28.jpg



Apply loctite to the screws

CE3DBC38-C970-411C-9ACD-3A7E760016F6-1909-00000387BA2C8AC9_zpsfeefb4cb.jpg



Pointed one goes onto the shaft that slides into the selector

25684756-B153-4ABF-B339-8114FAE08469-1909-00000387E0FE6BE7_zpseea534aa.jpg




Tighten this mutha####a up! And I mean tighten!


9C42E67D-AC43-46D7-9A96-E14ECFAEFE04-1909-000003880029CEB5_zps571c0558.jpg



Long grub screw now


F4C09CA1-A319-440E-8982-9FC8E1492AA4-1909-0000038823D64B37_zps6ce8511f.jpg


4119485E-1F73-4A91-95ED-61272D4905F0-1909-0000038844E67FDF_zps8f8fa0a1.jpg




Apply loctite again

27B03E11-336F-462F-8E56-18D7497242F6-1909-00000388656B2019_zps680588c2.jpg



Again torque the bastard!


E05FA52D-D97D-4CC4-979E-3028DCB91812-1909-0000038A097F99C0_zps741d7fde.jpg



You don't want them coming undone!


Step back and take a break


509B5A55-488C-45A2-A5D8-0BE0FB91AFD4-1909-0000038A2A10C277_zps28ef5a69.jpg


Remove the LT77 selector from your chosen storage space

275CA2E4-1A31-4D2E-8D99-32A2CD4CD254-1909-0000038A6C6EE14B_zpsad6a1d1f.jpg


F7B417CE-8F3D-423D-8270-034CD8DF62EE-1909-0000038A8F4AF41E_zps1f5ee495.jpg




Apply a good bead of sealant and begin assembly


D2B77618-0876-4DF6-8A46-3297923427DE-1909-0000038AA8C9970F_zps5613854f.jpg


48A55622-FE05-4FAE-B679-145A49D1DB91-1909-0000038ABE2A621F_zps19366e52.jpg



Locate it on dowel and remember where your bolts came from

CCBA4B10-155F-459C-9880-56F2678FE5C4-1909-0000038ADCC7E36C_zpsbcf831e1.jpg


Begin with the long bolt

B327393C-5514-4C03-BF8B-0CDB53BD7404-1909-0000038AF5D7936F_zps1708d64c.jpg


0EB9FEE8-4854-4323-82A9-2F9702BFD1C1-1909-0000038B099B385B_zpsed90b8f8.jpg


After this just tighten the buggers up, I found out I cant select the bottom set of gears too easily which on inspection looks to be the bias plate that needs some fettling so I'll sort that at a later date but for now thats a how to do it with pics :)


Hope that helps anyone who may be considering the same thing
 
Updated version (extra pic) and thanks, will have a go at it if I get a chance





Found the supposed problem according to Ashcroft and with some help from JM plus a lot of scouring of the parts manuals. I will confirm this tomorrow if I get a chance!


Theres a T piece that isn't needed within the LT77 selector housing if fitting it to the R380. The LT77 actually has 3 more pieces to it than the R380 mechanism

Anyway heres the pics



R380


Screenshot2013-03-06at164737_zps21ef072a.png


Screenshot2013-04-13at235010_zps90d321cd.png




And the LT77


Screenshot2013-04-13at235020_zps98832419.png



Screenshot2013-04-14at000205_zpsedfda32d.png






Heres the T piece that may be the problem!


Screenshot2013-04-14at000152_zpsfd062013.png



Screenshot2013-04-14at000200_zps5fe8ee83.png
 
no 12 in your in your parts list r380 has one but its secured into the front of rear housing by one bolt ,reverse plunger needs removing too
 
Removed the plunger as R380 reverse switch is in the box as far as I can tell (thing on passenger side with two wires)


Will remove the housing and update, as said goes in PM it stays in gear if held so would assume that its just not fully engaging as that things blocking it :)



I'll whip off the top and re-seal with more gasket tomorrow if I get the chance if not I'll do it when I fit the transfer box next weekend, would have been a lot simpler had I found that post on Ashcrofts site before I fitted it together :doh:
 
sweet, no need for relay in that case ?


if so will make up some wiring this week so its ready to plug in when I get the tub on and find a suitable LED bike light to use as a reverse light
 
Thanks :D your help on the matter was great too!


Wouldn't have gone down this route if you hadn't pointed me towards that old thread
 
All works now, removed the T and the old extra reverse plunger that was in the back of the selector and all gears select just fine now
 
Resurrecting this thread if you don't mind. In the eight months or so since you installed this conversion, how is it working? Any pros or cons to using the discovery box in the defender? I ask as I'm about to fit a 300tdi to my 90 which came from a discovery with the discovery box. I also have a V8 R380 box that I was thinking about have rebuilt with the proper input shaft to fit this conversion as well. Any thoughts would be much appreciated.

Cheers,
Chris
 
Resurrecting this thread if you don't mind. In the eight months or so since you installed this conversion, how is it working? Any pros or cons to using the discovery box in the defender? I ask as I'm about to fit a 300tdi to my 90 which came from a discovery with the discovery box. I also have a V8 R380 box that I was thinking about have rebuilt with the proper input shaft to fit this conversion as well. Any thoughts would be much appreciated.

Cheers,
Chris

the boxes are basically the same so no noticeable difference apart from selector mechanism,v8 boxes would need input shaft and bell housing,but still easy conversion i used to buy a lot of next to new ex mod v8 boxes and convert then to tdi ,when 300 tdi was introduced a lot of the parts in the drive train became common over the range of models ie disco rrc and defender
 
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Thanks for the response and if I understand you correctly if one was to install a kit like Doc made you would not be able to tell the difference when driving the truck? The difference being the def vs the disco trans.
 

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