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How to swap transfer boxes?

Geobloke

Geobloke

Posting Guru
Righteo then, I am going to be swapping Eva's current transfer box over to a disco transfer box in the next month or so and I need to know how!

Hugh do you fancy helping out?

IIRC there are only 5 bolts, the propshaft and hand brake assembly to undo, of course I could be completely making that up!!!!

Any advice?
 
Long time since I did one...:D :D

I can't remember the number of nuts/bolts but I do remember a nut on the front next to the gearbox,all covered in sh-one-tea that's hard to find.

Depends which handbrake.
If the latest cable type I'd be tempted to leave the cable on the backplate and move the backplate out of the way.
 
mmgemini said:
Long time since I did one...:D :D

I can't remember the number of nuts/bolts but I do remember a nut on the front next to the gearbox,all covered in sh-one-tea that's hard to find.

Depends which handbrake.
If the latest cable type I'd be tempted to leave the cable on the backplate and move the backplate out of the way.
Click to expand...

Old rod actuated type.

Just been told sommat about having to take the blanking plate off the back of the box to be able to separate the 2 gearboxesa form each other. Is that right?
 
no, no need to take the back plate off. once you have removed all the bolts, and unbolted the Hi/Lo lever from the gearbox is should be free to move back and forward on the mainshaft. take the handbrake drum off and pull the transferbox back just enough to clear the studs. You have to rotate the transfer box so that the handbrake and rear flange clear the little cross member just below the seat box.

let me know if you have any probs, me and nobber did this is the summer with mine ;)
 
ken110 said:
no, no need to take the back plate off. once you have removed all the bolts, and unbolted the Hi/Lo lever from the gearbox is should be free to move back and forward on the mainshaft. take the handbrake drum off and pull the transferbox back just enough to clear the studs. You have to rotate the transfer box so that the handbrake and rear flange clear the little cross member just below the seat box.

let me know if you have any probs, me and nobber did this is the summer with mine ;)
Click to expand...

Oh well thats excellent news Ken, excellent! :) Will let you know how it goes.

Dave I will be doing it at mums as there is a barn I can set up in, keep out of the worst of the weather!!!
 
I've got a set of guide pins you can borrow if you want... or I could make you set up for a small fee.

These pins are basically long studs that you screw in when you've got the old transfer box off. Then they simply act as guide when you slide the replacement transfer box on.


Ian
 
Porny said:
I've got a set of guide pins you can borrow if you want... or I could make you set up for a small fee.

These pins are basically long studs that you screw in when you've got the old transfer box off. Then they simply act as guide when you slide the replacement transfer box on.


Ian
Click to expand...

Ian you star! will PM you now. :) :)
 
Porny said:
I've got a set of guide pins you can borrow if you want... or I could make you set up for a small fee.

These pins are basically long studs that you screw in when you've got the old transfer box off. Then they simply act as guide when you slide the replacement transfer box on.


Ian
Click to expand...
Funny thing. I have a set of guide pins as you call them for doing the main gearbox. It's not entered my head to make two for the transfer box job. :eek:
 
if you do as earch for posts by 'bhmor', bob had uploaded a picture detailing all the bolts holding it on to help someone else with the swap.

i used it to do mine and it was very helpful.

remember to get some freinds to help, and some jacks, they are remarkably heavy and a fairly **** thing to have drop on any part of you.
 
Well hot diggidy damn I have just completed the transfer box swap. Had some irritating difficulties that meant the job took way way way longer than it should have done, but it is done. Test drive tomorrow morning.

Cheers to, Neil, Lewis, Hugh and David for your help.
 
I'll bet it was re-connecting the hi-lo gear lever....or maybe realising that the disco transfer case has one too may studs in it for the back enf of your gearbox... we noticed this after messing about for 1/2 an hour...
 
ken110 said:
I'll bet it was re-connecting the hi-lo gear lever....or maybe realising that the disco transfer case has one too may studs in it for the back enf of your gearbox... we noticed this after messing about for 1/2 an hour...
Click to expand...

Well! I had no trouble with the hi-low lever and I did realise that the disco box had an extra stud where the defender one had a bolt, certainly was a head scratcher moment for sure!

The headaches were when I was trying to line the box up and the splines of the new gear and then realising that the brake back plate was buckled and dented to such an extent that the drum locked on tight when done up!!! :eek: :eek:

Thankfully the defender and disco back plates were identical and they slide off over the drive flange too. Was a moment when I though I would have to take the flange off first!!!!

All of the little problems just made for a drawn out tiring long day!!
 
With the lack of anything sensible to lift the gearbox up I improvised a little and possibly went a bit OTT as well! Having said that it worked a treat!!!! :D
 

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OTT....hmm Mine and nobbers approach cosisted of loosening the transferbox and wraping a rope around my waist which was looped around the box and lowering to the ground (lifting with my legs and all that...:D)

worked though! :)
 
Geobloke said:
Well hot diggidy damn I have just completed the transfer box swap. Had some irritating difficulties that meant the job took way way way longer than it should have done, but it is done. Test drive tomorrow morning.

Cheers to, Neil, Lewis, Hugh and David for your help.
Click to expand...
WELL.... how does it drive?
 
LandyV8 said:
WELL.... how does it drive?
Click to expand...

Well thus far excellent, i have only driven just over 100 miles with it and it will take a little bit to get used to the gearing, but yeah very happy :)

Might have to fiddle with the fueling to compensate for the taller gears, but will leave it a week or so until I can get used to the drive.

How's the 110 mate? all better?
 
Glad it's all ok.

Geobloke said:
How's the 110 mate? All better?
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Yes, Finally. Went up to Beths in Lancaster in it the other weekend just to see how it was with the road tyres on and it drove very well. Fuel consumption for the journey worked out to be 14mpg. That's motorway and around town in Lancaster and back home in Bolton. That's a lot better than the 8 mpg before. Just running on petrol for now until the engine has had chance to settle in. I'll try with LPG when I've done 1000 miles. eak that's a lot of petrol lol
 
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