Fitted my shiny new Disco transfer box and the difference is amazing. Can cruise nicely at 60 now without the noise. Lovin it already.

Next job is to fit my new suspension and rebuild a swivel

Got one of them lying in my garage. It's got to make a big difference from my 1.6 military transfer box. Did you take any photos whilst fitting it?
 
I didn't but it really was straightforward. Hardest part was lifting the new box up and on, they weigh a ton. Only modification I had to make was to drill and tap two holes for the defender handbrake bracket but that was easy. All you have to do is chock wheels, remove front and rear props, remove handbrake drum assembly, remove handbrake bracket from the side of the box, remove handbrake backing plate, remove speedo cable, remove hi/low linkage and diff lock linkage from box. Then just drain the old box and its just a case of taking out 4 volts at the rear, two at top and two on the left side. At the front you have two threaded studs, just on the left when it fits snuggly against the gearbox, remove the nuts from these. After that with a bit of wiggling the box will come free but you need to support it as its heavy bit of kit. Could use an engine crane but I just rigged up a pulley to take the weight and lowered it down. You may need to transfer the threaded studs onto the new box but that's easy. Fitting new box is reverse of what you just did
 
I didn't but it really was straightforward. Hardest part was lifting the new box up and on, they weigh a ton. Only modification I had to make was to drill and tap two holes for the defender handbrake bracket but that was easy. All you have to do is chock wheels, remove front and rear props, remove handbrake drum assembly, remove handbrake bracket from the side of the box, remove handbrake backing plate, remove speedo cable, remove hi/low linkage and diff lock linkage from box. Then just drain the old box and its just a case of taking out 4 volts at the rear, two at top and two on the left side. At the front you have two threaded studs, just on the left when it fits snuggly against the gearbox, remove the nuts from these. After that with a bit of wiggling the box will come free but you need to support it as its heavy bit of kit. Could use an engine crane but I just rigged up a pulley to take the weight and lowered it down. You may need to transfer the threaded studs onto the new box but that's easy. Fitting new box is reverse of what you just did

You make it sound quite easy, I don't know why, but it's a job I keep putting off - just don't fancy doing it. Do you drain the transfer box and gearbox or just gearbox? What transfer box did you have before, a 1.4?
 
Just drain the transfer box, 17mm magnetic sump plug on the bottom. I had the standard 1.4 yeah and I notice the difference so you probably will even more so. And it is easy. Just be prepared to get very very dirty
 
Just drain the transfer box, 17mm magnetic sump plug on the bottom. I had the standard 1.4 yeah and I notice the difference so you probably will even more so. And it is easy. Just be prepared to get very very dirty

bull**** metric measurements :p learn to work in imperial!
 
You make it sound quite easy, I don't know why, but it's a job I keep putting off - just don't fancy doing it. Do you drain the transfer box and gearbox or just gearbox? What transfer box did you have before, a 1.4?

yeah it is easy, if you have a 300tdi+ and use the newer style handbrake then it's easier as no handbrake mod.

it's just heavy and awkward. i might be down again in a couple of months.. i could probably wangle a few hours to give you a hand if you want :)
 
yeah it is easy, if you have a 300tdi+ and use the newer style handbrake then it's easier as no handbrake mod.

it's just heavy and awkward. i might be down again in a couple of months.. i could probably wangle a few hours to give you a hand if you want :)

That's a very kind offer. You're about the third person to offer to help me from Landyzone, which is great. The plan is to get you all around at the same time, you can then help each other and I can just drink tea and supervise :)

I really feel it's something I should just get on with and do myself. I have an engine crane to take the weight, so it should doable on my own.
 
Busy day today made my spare wheel carrier with a Hi Lift mount as well:D.


spare.jpg




spare1.jpg
 
Not got pics for either of these as I left my phone at my dads...

Made some new fuel line pickups for my fuel tank as the out was in the wrong direction and the in was going into the fuel which I think was causing a backup of fuel from the swirl pot.

Also made a pin for a tow bar that my mate gave me. 1" bar, built up some weld on one end and tuned it to shape and drilled a hole in t other end for a R clip.
Looks just like this..

 
Well I fixed my electric fan today to try and keep the temp down a bit as driving with the heaters on in this weather isn't very nice.

Also used it to move this car I've stripped now the fan works as it gets a bit hot when towing.

emyga3uj.jpg
 
Thanks for the comments guys:D





nicely done!

you have a proper bender for bending the tube?

you cut all the metal with an angle?

I do have a pipe bender but i would hardly call it proper it is about 70 yrs old and i piece of shat realy but it does help me a bit.:D
 

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