We are just swapping my mates 1.41 transfer box over in his Td5 Defender for a 1.222 Disco box (from a 300). However, we've hit a snag. There is no hi/lo sensor switch on the 1.222 box. What do we do?

Do we need to swap the casing over where the switch is located? Do we need the switch?

Any help would be much appreciated.

Thanks

your not stuck .and dont swap casing as this contains selectable shim for diff bearing behind outer race of front diff bearring chances both are the same and diff preload not altered are slim, you dont need hi/low switch which tells ecu car is in low,so disconnected ecu will think its allways in high ,you could fit a switch so that the circuits made between two wires going into switch so ecu knows your in low if you wanted fitted in cab but you would have to operate it yourself

Thanks James. I'll disconnect the hi/low switch then and keep it disconnected. Just for future reference, why does the ECU need to know it's in low if it doesn't actually need connecting?

Also, we've just noticed the speedo connector is different as well as the diff lock sensor. Can we just swap over the speedo sensor over and snip and rejoin the wires on the diff lock sensor to the existing loom?

just swap speedo parts , swap diff lock switch or join wires

ECU makes the throttle less sensitive when in low range. You will notice that in high range full throttle is at about half pedal potentiometer travel where as in low range you need full travel for full throttle.

I've had my ECU fuel map modified so that it uses full travel at all times which makes driving much smoother in high range on bumpy ground. Effectively the ECU thinks its in low range at all times no matter what the transfer box switch says.

In your case you can just leave things unconnected or you could try shorting the hi/lo switch to see the difference in throttle response. Only drawback with this method is the LOW range indicator will be lit at all times. Try it and see what you prefer.

Cheers James and Shifty...will hopefully get it sorted tonight