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#Post#: 96700--------------------------------------------------
Re: Series gearbox
DIR By: defibf
Date: March 18, 2015, 12:24 pm
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I have an lt77 (long stick), with switchable 2wd/4wd Lt230
(disco ratio) in my S2 109, turbo diesel (transit), it was work
to fit but much nicer to drive than the series box with o/d, and
less risk of box failure. The ratios suit the turbo diesel
perfectly
One thing to look for in purchasing an LT77 is the transfer case
drive gear, they wear the main shaft due to lack of lubrication.
If you feel play walk away :) mine was good, it was supposedly
rebuilt 1000 miles prior to writing off the vehicle it was
fitted in. I cross drilled the gear when I swapped the disco
LT230 transfer case and modified the diff for switchable 2wd/4wd
I had a "spool" made for the diff which I welded to the spider
gear shafts and spider gear, the diff was machined to fit a
roller bearing in the "front" section (facing front of vehicle)
to support drive shaft when not connected to spool, I have seen
others do this with a needle roller brg, but didn’t like this so
went with roller brg. You will need to either chop out some of
the cross member or extend the front prop, I had an extension
made for the prop out of "air craft" alloy (don’t recall spec of
top of head) its lightweight and strong so shouldn’t cause
problems with o/p bearing
I morphed a defender trans tunnel to the S2 bulkhead and seat
box, I kept the S2 rod handbrake, buy fabricating a "link" and
moving handbrake pivot down and back, it works well :(
That was 2 years ago been fine since fitting, I am running the
Lt77 on full synthetic and the Lt230 on semi synth
#Post#: 96711--------------------------------------------------
Re: Series gearbox
DIR By: Texpis
Date: March 19, 2015, 4:04 am
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Cheers defibf and welcome to the forum Newby like me. You guys
that have 5 speed boxes have you photos of the interior floors
etc? Do you use the origional floor tunnel or one out of a
defender?
Mick
#Post#: 96715--------------------------------------------------
Re: Series gearbox
DIR By: Harry2a
Date: March 19, 2015, 10:45 am
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I used the kit from ashcroft to change to part time 2wd. And as
mentioned by defibf, the input gear is an issue, so I also
swapped the input gear for a later cross drilled type from
ashcroft while i was in there. Im planning to use a defender
tunnel. originalitys one thing but the 230 has other advantages,
like being able to switch 4wd to 2wd and out on the move. And
hopefully will be quieter!
#Post#: 96722--------------------------------------------------
Re: Series gearbox
DIR By: Texpis
Date: March 20, 2015, 11:22 am
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Hi and thanks for the replies. I have been looking at my present
gearbox hoping to get a few months while I collect the parts I
need for a 5 speed conversion. The box that is in now was a
reconditioned box but 6 months after instal it started sticking
in 3 gear. The PO was going to remove and send back but because
of family problems it got dumped into the back garden where it
stayed for a few years till I got it.
I have now got it back on the road I have been looking at the
gearbox it does stick in third but also jumps out of second and
crunches when going 3 to second. I have found the main nut loose
which I have tightened but there seems a lot of float on the
mainshaft when changing gear anyone know if this is normal
Mick
#Post#: 96723--------------------------------------------------
Re: Series gearbox
DIR By: defibf
Date: March 20, 2015, 1:45 pm
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Cheers defibf and welcome to the forum Newby like me. You guys
that have 5 speed boxes have you photos of the interior floors
etc? Do you use the origional floor tunnel or one out of a
defender?
Mick
Cheers :)
I morphed ( cut and shut then tig welded) the defender trans
tunnel into the bulkhead and seatbox
I will try to find pictures of diff conversion and get round to
taking pictures of trans tunnel
#Post#: 96725--------------------------------------------------
Re: Series gearbox
DIR By: Serious Series
Date: March 20, 2015, 2:10 pm
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Sounds like the snap ring inside the third gear has broken holds
the gear in place at the synchro end.
#Post#: 96727--------------------------------------------------
Re: Series gearbox
DIR By: defibf
Date: March 20, 2015, 4:41 pm
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Image of cross drilled gear
HTML http://farm8.staticflickr.com/7007/6749864213_4ac257abf9_z.jpg
Spool fitted to diff, doesn't show spool welded to rear spider
gear, these are the only images I could find I must have deleted
the others
HTML http://farm8.staticflickr.com/7029/6749865097_5c2e5fb433_z.jpg
#Post#: 100417--------------------------------------------------
Re: Series gearbox
DIR By: Texpis
Date: January 10, 2016, 2:21 pm
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Well she's nicely up and running lt77 with series gearbox and
cologne 2.9 V6. Changed from Range Rover diffs back to standard
series diffs as the gearing wasn't low enough for trailing.
HTML https://youtu.be/tvuuJOuPEP8
#Post#: 100426--------------------------------------------------
Re: Series gearbox
DIR By: Arjan
Date: January 11, 2016, 3:04 am
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Just what does "..modified the diff for switchable 2wd/4wd..."
really mean, work wise.
Just collected a complete Disco I drive train (200 Tdi) and
have a dead Series tranmission at the moment....
#Post#: 100428--------------------------------------------------
Re: Series gearbox
DIR By: Texpis
Date: January 11, 2016, 5:20 am
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I didn't modify the transfer box I used the series transfer box
and moved the engine forward so everything in the cab is the
same. The modify the dif refers to using the lt230 transfer box
and welding up the transfer box internal diff there is a write
up how to do it, but you also need to do mods to the gearbox
crosmmember.
Mick
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