Discovery 2
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knappster
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PostPosted: Tue Nov 27, 2018 5:43 pm    Post subject: Reply with quote
Thatís good news then. Not often a repair is cheaper than you planned, especially with a Landy!

Driving the 110 again, youíll want to keep it... Smile and youíll get the Landy waves again too. Wink Disco drivers donít really get waved at.
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Rich.

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BigJohn
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PostPosted: Fri Nov 30, 2018 6:26 pm    Post subject: Reply with quote
O.K. things just got worse - much worse.
I'm digging around in the transfer case and I found transverse play in the final drive shaft. I eventually pulled the rear output shaft out (slide hammer job) and found that the rear mainshaft taper roller bearing had broken up. Also the end of the mainshaft is being reamed out by the tailshaft as the only thing supporting it is the rear output shaft bearing. This cannot be fixed without removing the transfer case. I can repair it, but the parts alone would probably cost more than a good used box.
The end result now is a replacement transfer box. I've hunted around and found one at a breakers near Coventry from a V8 automatic with only 67000 miles on the clock (barely run in). They even checked the MOT history to be sure. This is due to turn up in the next few days. This will be the right match for mine as the later crossdrilled LT230s have longer splines on the input gear (as mine has) so it will be a straight swop. I'll make a lifting bracket to aid lifting it in. There will be some wiring differences, but that will be easy to deal with.

Lessons to be learned.
The cause of the problem is ignorance of Land Rover transmission by the previous owner(s). Although this car has obviously been generally looked after and has never been off road, it has had an oil leak for some years which was never attended to. I suspect it has run for many thousands of miles with very little oil in the transfer case. It probably didn't drip oil because there was almost none in there!!!!

Always check ALL of your oils. Remember that the input shaft and final drive in LT230 transfer boxes are only splash lubricated by oil being thrown around by the intermediate gears.
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TD5 Discovery.

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PostPosted: Fri Nov 30, 2018 10:56 pm    Post subject: Reply with quote
Just when you think you've got it sussed....
Bad luck John, it really is a Land Rover Very Happy
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BigJohn
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PostPosted: Sat Dec 01, 2018 7:26 pm    Post subject: Reply with quote
I have to say though that I'm sold.
Apart from the gearbox issue, the Disco is a great vehicle to drive.
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PostPosted: Sat Dec 01, 2018 10:30 pm    Post subject: Reply with quote
Will you be changing it undercover or are you going to wait for a dry day? Confused
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First Landy back in the 1980's

1972 88" Hard top with windows (Daisy)

Previously my daily drives:
109" Series three station wagon
110" Hard top with windows
109" FFR pick up, 24 volt
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BigJohn
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PostPosted: Mon Dec 03, 2018 4:39 am    Post subject: Reply with quote
Unfortunately it's going to be done outside. I can't get the Disco inside. It has to be jacked up very high for this job. Fortunately I have portable floodlights so I can see what I am doing.
My Dad, who is 93, is currently in hospital in Southampton after breaking his hip, so I need to get it repaired to go down and visit him. It's either that or take the 110 on a 350 mile round trip, and Mrs BJ, unsurprisingly, is not keen as she likes a bit of comfort.
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TD5 Discovery.

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BigJohn
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PostPosted: Wed Dec 05, 2018 4:07 pm    Post subject: Reply with quote
Well the transfer box came out without too much drama. Just waiting for the replacement to arrive tomorrow. Should be back on the road in a couple of days.
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PostPosted: Wed Dec 05, 2018 7:21 pm    Post subject: Reply with quote
BigJohn wrote:
Well the transfer box came out without too much drama. Just waiting for the replacement to arrive tomorrow. Should be back on the road in a couple of days.

Unless it rains Sad
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First Landy back in the 1980's

1972 88" Hard top with windows (Daisy)

Previously my daily drives:
109" Series three station wagon
110" Hard top with windows
109" FFR pick up, 24 volt
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BigJohn
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PostPosted: Thu Dec 06, 2018 6:16 pm    Post subject: Reply with quote
The replacement transfer box is in - well more or less in - still got to round the bolts and tighten up, fill it with oil, handbrake and propshafts back on, rebuild the insides and have a good cleanup, but that's only a couple of hours work.
It took me about 40 minutes and about 20 tries to get the gearbox splines to line up Sad Then suddenly it just popped in. Same as changing engines.

I had a very enjoyable hot shower afterwards.

Anyway, we will be back on the road tomorrow Very Happy
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TD5 Discovery.

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Adie
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PostPosted: Thu Dec 06, 2018 7:00 pm    Post subject: Reply with quote
Nice one BJ. I have to say grovelling around under any Land Rover gearbox/transfer case is never going to be a clean affair! EP90 does stink and lingers for days!! I can imagine that hot shower after was bliss! At least the hard work is done!
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knappster
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PostPosted: Thu Dec 06, 2018 8:30 pm    Post subject: Reply with quote
Result! Cool
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Rich.

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BigJohn
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PostPosted: Fri Dec 07, 2018 4:02 pm    Post subject: Reply with quote
Transplant complete Very Happy
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TD5 Discovery.

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PostPosted: Fri Dec 07, 2018 4:18 pm    Post subject: Reply with quote
Nice.

You have taken notes and made a 'how to' video on this little job, haven't you John.

Frank could do with a 'write up' too. Very Happy Very Happy Very Happy

Seriously, good job. Surprised you had dry weather in welsh Wales, bit damp down here.
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First Landy back in the 1980's

1972 88" Hard top with windows (Daisy)

Previously my daily drives:
109" Series three station wagon
110" Hard top with windows
109" FFR pick up, 24 volt
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frank
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PostPosted: Sat Dec 08, 2018 9:16 am    Post subject: Reply with quote
A write up would be good, please
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BigJohn
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PostPosted: Sat Dec 08, 2018 6:39 pm    Post subject: Reply with quote
Frank,
I will see what I can do.
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