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  1. #1
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    Default My Disco 1 LT230 Transfer box rebuild thread

    While my gearbox is out, I'm going to open the transfer box and inspect. Clearly it has been opened in the last few years, since it isn't leaking and I can still smell the sealant on the bolts.

    I was going to just leave it, but there are two reasons why I might end up doing at the very least an inspection and seal renewal.

    1. It was a hell of a job to pull this gearbox, and I would like to do what I can in one fell swoop.

    2. This: (and a lot of these goldish particles in the oil I drained).



  2. #2
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Are those copper it could be from the center diff spider gears shims only thing that is copper in the LT230,
    if you strip it you will need a new crush tube for the intermediate gear, if you change any bearing you will need to do preload with the correct shims, I had to order shim kit from UK Ashcrofts when did mine, lot of ppl just use same shims that came out and might be lucky to get the right preload

    not a hard box to strip and overhaul and full bearing kit not that bad think about 2K
    Last edited by clivemd; 2021/07/11 at 08:56 AM.
    1995 300TDi Defender with VGT Turbo (stolen by my son now )
    2002 Defender with LS1 MS3 ECU, 4L80e, LT230 1.222, Lockers and HD CW&P, 35" with 4" Lift
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  4. #3
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Will follow this thread closely. Need to fix a leak on mine-between autobox and transfer (d2 auto).
    I have a thud when selecting reverse so hopefully that is something that I can sort with shimming properly. Some clown did a rebuild of the front output shaft on the lt230, but I think he was just that, a clown.
    '99 TD5 Hardtop
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    It's a Land Rover thing... and I get it now 8)

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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Oh and for the input seal get a viton seal they take the heat better then normal ones
    1995 300TDi Defender with VGT Turbo (stolen by my son now )
    2002 Defender with LS1 MS3 ECU, 4L80e, LT230 1.222, Lockers and HD CW&P, 35" with 4" Lift
    2005 Defender TD5

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  7. #5
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    clivemd, always such useful input, thank you.

    Yes, I am suspicious about the spider if this is the original box which I think it is. I'm kicking myself for selling my old box from the previous disco, which had an uprated spider.

    Bearing and seal kit comes to about R4k now from a popular landy spares place. I was also surprised how much it went up. But still worth it.



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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Quote Originally Posted by antvz View Post
    clivemd, always such useful input, thank you.

    Yes, I am suspicious about the spider if this is the original box which I think it is. I'm kicking myself for selling my old box from the previous disco, which had an uprated spider.

    Bearing and seal kit comes to about R4k now from a popular landy spares place. I was also surprised how much it went up. But still worth it.
    I donít use the paper gaskets just sealant vitor renz ( spelling) and on the bolt threads I use Wurth PTFE pipe sealant, and use Tinken bearings
    have you got the LT230 manual
    1995 300TDi Defender with VGT Turbo (stolen by my son now )
    2002 Defender with LS1 MS3 ECU, 4L80e, LT230 1.222, Lockers and HD CW&P, 35" with 4" Lift
    2005 Defender TD5

  9. #7
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Ok so here is another possible explanation.
    I did some work on my rear output sharf housing, a seal I think.
    I also found some copper but it was extremely thin.
    After enquiring on a few forums, I was told that during assembly they put a very tin copper shim in some parts.

    This is apparently a sacrificial shim and only needed to ensure the correct clearance and end float.
    I can't prove it but if it is very thin I don't think it's the washers.

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    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind≤)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
    The only thing needed for evil to triumph is for a good man to do nothing.

  10. #8
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Quote Originally Posted by clivemd View Post
    I donít use the paper gaskets just sealant vitor renz ( spelling) and on the bolt threads I use Wurth PTFE pipe sealant, and use Tinken bearings
    have you got the LT230 manual
    Yes, I have the manual lurking on my PC somewhere...



  11. #9
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Quote Originally Posted by jfh View Post
    Ok so here is another possible explanation.
    I did some work on my rear output sharf housing, a seal I think.
    I also found some copper but it was extremely thin.
    After enquiring on a few forums, I was told that during assembly they put a very tin copper shim in some parts.

    This is apparently a sacrificial shim and only needed to ensure the correct clearance and end float.
    I can't prove it but if it is very thin I don't think it's the washers.

    Click image for larger version. 

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    The piece in my photo is quite a decent chunk of copper. Just my luck.

    But all will be revealed when I have the cover off.



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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Quote Originally Posted by antvz View Post
    Yes, I have the manual lurking on my PC somewhere...
    Attached Images Attached Images
    Cheers,
    John Kilfoil

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  14. #11
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Hi Antvz

    I think those copper pieces is from the copper cone washers that is in the centre diff. There are 4 of those washers that are installed in the cross axles of the planetry gears withing the centre diff.

    When I opened my LT230 for a rebuild, that washers was paper thin worned, I think yours have collapsed.

    Rebuilding a LT230 is a good learning experience ahead of the R380 which is a little more complex but I agree you must use a manual just to keep track.

    I made a modification while I was working on mine with the intermediate shaft that is prone to leaking at rhe o ring end.

    I wonder if the D1 has a different gear setup as the Defender one? I always wonder about a gear ratio change in the T - case just to help the final drive a bit.

    Please post pictures as you move along, its an interesting read.
    Here are from my rebuild
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    Barry Enslin

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  15. #12
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    @JohnnoK thanks, this is a good resource to have posted up on this thread.
    Last edited by antvz; 2021/07/11 at 11:25 AM.



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  17. #13
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Quote Originally Posted by Wildkyker View Post
    Hi Antvz

    I think those copper pieces is from the copper cone washers that is in the centre diff. There are 4 of those washers that are installed in the cross axles of the planetry gears withing the centre diff.

    When I opened my LT230 for a rebuild, that washers was paper thin worned, I think yours have collapsed.

    Rebuilding a LT230 is a good learning experience ahead of the R380 which is a little more complex but I agree you must use a manual just to keep track.

    I made a modification while I was working on mine with the intermediate shaft that is prone to leaking at rhe o ring end.

    I wonder if the D1 has a different gear setup as the Defender one? I always wonder about a gear ratio change in the T - case just to help the final drive a bit.

    Please post pictures as you move along, its an interesting read.
    Here are from my rebuild
    Thanks for the pics.

    The Disco has a slightly "taller" ratio than the Defender and quite a few people do this mod to give their Defender slightly longer legs.



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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Quote Originally Posted by Wildkyker View Post
    I wonder if the D1 has a different gear setup as the Defender one? I always wonder about a gear ratio change in the T - case just to help the final drive a bit.
    D1 is the same as D2, Defender & Range Rover, only ratios are different.
    Range Rover Classic has a 1:1 ratio that will stretch the legs nicely.
    Cheers,
    John Kilfoil

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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Quote Originally Posted by JohnnoK View Post
    D1 is the same as D2, Defender & Range Rover, only ratios are different.
    Range Rover Classic has a 1:1 ratio that will stretch the legs nicely.
    Edit: Have to correct myself from earlier incorrect data
    The original classic RR with LT95 4-speed gearbox with integral transfer had HR ratios of 1.174 and later 1.113
    The Vogue 4-speed manual gearbox classics had 1.1:1 HR transfer ratio, which was later changed to 1.1227 HR transfer ration for standard compression engines and 0.9962 HR transfer ratio for high compression engines. These were also LT95 inegral transfer boxes.
    When the Vogue got the LT77 5 speed manual box with LT230R transfer boxes the HR tarnsfer ratio changed to 1.192
    The closest the LT230 came to 1:1 HR ratio was when fitted behind the 3-speed Chrysler automatic, HR ratio was the 1.003.
    When 4 speed ZF auto box were fitted, LT230 HR ratio changed back to 1.192, up to 1989.
    From 1989 the Borg Warner chain driven transfer box was fitted to the classic RR, high range ratio 1.206.
    All tarnsfer boxes (LT95 integral and LT230) had 3.32 low range ratios, except for the Borg Warner with 3.244
    Last edited by Mike N; 2021/07/12 at 12:06 PM.
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  21. #16
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Quote Originally Posted by jfh View Post
    Ok so here is another possible explanation.
    I did some work on my rear output sharf housing, a seal I think.
    I also found some copper but it was extremely thin.
    After enquiring on a few forums, I was told that during assembly they put a very tin copper shim in some parts.

    This is apparently a sacrificial shim and only needed to ensure the correct clearance and end float.
    I can't prove it but if it is very thin I don't think it's the washers.

    Click image for larger version. 

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    Click image for larger version. 

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    I think the shims you are talking about are the same washers the others are talking about.

    The whole thing is quite well documented on other forums and elsewhere on the Internet.



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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    So with all of the above useful information from you guys, I opened the inspection hatch in the transfer box today. There was a bit more of the copper stuff.

    All the gears looked fine. There is evidence that the whole thing has been removed and resealed at some stage in the past (so now I'm fairly sure the transfer box was done and at the same time the gearbox governor was cleaned out) - my guess is that all this was done around 2016 before the previous owner bought the car. The transfer box wasn't noisy or difficult to get into gear at all, so everything seems fine.

    With all this in mind, I did something that I really hope won't come to bite me in the near future - I closed it up again and put it back in the garage, ready for reattaching to the gearbox once I'm finished with that.



  23. #18
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Quote Originally Posted by antvz View Post
    So with all of the above useful information from you guys, I opened the inspection hatch in the transfer box today. There was a bit more of the copper stuff.

    All the gears looked fine. There is evidence that the whole thing has been removed and resealed at some stage in the past (so now I'm fairly sure the transfer box was done and at the same time the gearbox governor was cleaned out) - my guess is that all this was done around 2016 before the previous owner bought the car. The transfer box wasn't noisy or difficult to get into gear at all, so everything seems fine.


    With all this in mind, I did something that I really hope won't come to bite me in the near future - I closed it up again and put it back in the garage, ready for reattaching to the gearbox once I'm finished with that.
    Hopfully it will be ok, we have gone to 85W-140 oil now on are T-cases and Diffs
    Attached Images Attached Images  
    1995 300TDi Defender with VGT Turbo (stolen by my son now )
    2002 Defender with LS1 MS3 ECU, 4L80e, LT230 1.222, Lockers and HD CW&P, 35" with 4" Lift
    2005 Defender TD5

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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Used the same in my 110
    Jakes Louw
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    Default Re: My Disco 1 LT230 Transfer box rebuild thread

    Quote Originally Posted by jelo View Post
    Used the same in my 110
    I remember an indy or two telling me they switched to this, too.

    85W140 is thicker and more heavy-duty if I understand right.

    Ironically I've just bought 10 l of 80W90 Caltex (Havoline) - have a depot in Polokwane and I've been buying all their products, from Delo 400 for the engine, their coolant, ATF and now GL5.

    I wonder if I should go back and swop it out. I've always used 80W90 in all the diffs just because this is the spec.



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