Disco Tcase in Defender 200tdi - Defender Source
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  #1  
Old May 26th, 2011, 01:26 PM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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Disco Tcase in Defender 200tdi

Swap finished (thanks Vinny)


Totally transforms the truck:

I can hear myself think at highway speed
I dont have to shift 3 times in an intersection
Top speed is well above 80mph

I came from a roller bearing 1.6 to the newer disco 1 case. Used RRC parts to make the ebrake work
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  #2  
Old May 26th, 2011, 01:42 PM
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Frank Rafka
01 D2 96 D1 83 110
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is yours behind a lt77? I have a 1.2 tcase sitting on the floor, just gotta find time to install it
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  #3  
Old May 26th, 2011, 01:46 PM
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Matthew
1983 110 200tdi 3 door soft top
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yea 200tdi:lt77:Lt230 1.2


so much better


Forgot to mention my truck is a 110
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  #4  
Old May 26th, 2011, 01:57 PM
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Tony Lawson
1986 D110 ex-200tdi to be 6BT
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I was always worried the 200 would lose pull in high gear with the 1.2. Not so? How about hills?
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  #5  
Old May 26th, 2011, 02:15 PM
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Matthew
1983 110 200tdi 3 door soft top
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Well im doing close to 55 in 4th gear now. Went up a few small hill and the drivieablility wasn't affected.


with the old tcase on ultra steep roads near my house I would be doing 40-45 in 5th with no problem. So im expecting the same here in 3rd

Im taking a 800 mile trip this weekend, ill let you know how it turns out.
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  #6  
Old May 27th, 2011, 02:45 PM
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Mike Simpson
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I'm thinking about doing the same thing. Just two questions. Is your LT77 the MOD box, which has lower first, second and .83 OD? Second, what is your tire size?
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  #7  
Old May 27th, 2011, 04:38 PM
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Jamie Austin
1992 110 Td5 CSW & 1989 MB G-Wagen
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Military boxes (suffix 51A) have only lowered 1st & 2nd... 5th is as a civvy box (although depends if it's an LT77 or LT77S)

I've got the part numbers here for the lowered 1st and 2nd gears if anyones wants?
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  #8  
Old May 28th, 2011, 02:17 AM
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Andrew
exmod 90 2.5na and a 93/RRC 200tdi
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http://rovers.red90.ca/gears.html

Quote:
LT77/LT77S Manual Gearbox
Model
Box S/N
1st
2nd
3rd
4th
5th
Reverse
90/110 British Military
51A
3.985
2.519
1.5074
1.00
0.8314
3.701
90/110 pre' 200TDI
50A
3.585
2.3008
1.5074
1.00
0.8314
3.701
Disco 200TDI
90/110 200TDI
55A
56A
3.692
2.132
1.397
1.00
0.77
3.429
90/100 V8
Disco V8
60A, 61A
53A, 57A
3.321
2.132
1.397
1.00
0.77
3.429
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  #9  
Old May 28th, 2011, 09:37 AM
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John B.
1991 Defender 90, 200TDI
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Quote:
Originally Posted by diesel_jim View Post
.. 5th is as a civvy box (although depends if it's an LT77 or LT77S)
Yes, but the LT77S that came with the 200TDI has a higher 5th and is makes a big difference in your choice, in my opinion.

Personally, I have a 51G box with a 1.2 Disco case. I love it. On road power is no different than with the 1.4. The power band is quite flat, so the gearing change made little noticeable difference. Basically it is quieter and more comfortable at higher speed and you don't run out of gears like I did with the 1.4.

However, on steep hill starts, 1st is a little tall requiring some clutch slip. I'm not sure I would like it in a 110.
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  #10  
Old May 28th, 2011, 11:15 AM
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Quote:
Originally Posted by Red90

Yes, but the LT77S that came with the 200TDI has a higher 5th and is makes a big difference in your choice, in my opinion.

Personally, I have a 51G box with a 1.2 Disco case. I love it. On road power is no different than with the 1.4. The power band is quite flat, so the gearing change made little noticeable difference. Basically it is quieter and more comfortable at higher speed and you don't run out of gears like I did with the 1.4.

However, on steep hill starts, 1st is a little tall requiring some clutch slip. I'm not sure I would like it in a 110.
I swapped out 1.2 gears and now I'm running 1.4 gears behind a 55A LT77 trying to turn 35" tires in my 110. It's great for the most part, but towing and starting on hills can be challenging. Next change is 4.11 gears.
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  #11  
Old May 28th, 2011, 01:27 PM
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Quote:
Originally Posted by Wolf Fabrication View Post
I swapped out 1.2 gears and now I'm running 1.4 gears behind a 55A LT77 trying to turn 35" tires in my 110. It's great for the most part, but towing and starting on hills can be challenging. Next change is 4.11 gears.
TDI? Do you have the fueling turned up?

I'm on 34s with a 200TDI. Seems strange you feel a need to go lower than stock (for the road) with 35s and a TDI.
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  #12  
Old May 28th, 2011, 03:01 PM
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Tom Paluska
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I have a 200 TDI LT77 110 with a Disco 1 transfer case. Highway RPM's are much lower and improved on road driveability but climbing hills here in Colorado is compromised. 5th gear is useless for the most part. Still in the process of up-tuning my turbo, intercooler so my results may not match a better tuned machine. I'm downshifting often to 3rd - to hold speed on I-70 climbs.

Tom

Denver
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  #13  
Old May 28th, 2011, 03:13 PM
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Quote:
Originally Posted by Red90

TDI? Do you have the fueling turned up?

I'm on 34s with a 200TDI. Seems strange you feel a need to go lower than stock (for the road) with 35s and a TDI.
Yep, TDI. Haven't messed with the fueling, but did turn up the boost. Like I said, the truck has near perfect gearing for the road, but hills kill it in 1st gear.
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  #14  
Old May 28th, 2011, 03:48 PM
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Quote:
Originally Posted by Wolf Fabrication View Post
Yep, TDI. Haven't messed with the fueling, but did turn up the boost. Like I said, the truck has near perfect gearing for the road, but hills kill it in 1st gear.
Turn up the off boost fueling. It goes a long way to reducing turbo lag and help with starting off in 1st.
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  #15  
Old May 29th, 2011, 12:30 PM
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Mike Simpson
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Quote:
Originally Posted by paluskat View Post
I have a 200 TDI LT77 110 with a Disco 1 transfer case. Highway RPM's are much lower and improved on road driveability but climbing hills here in Colorado is compromised. 5th gear is useless for the most part. Still in the process of up-tuning my turbo, intercooler so my results may not match a better tuned machine. I'm downshifting often to 3rd - to hold speed on I-70 climbs.

Tom

Denver
This is very helpful for me. I've got a 200tdi that I'm going to swap into an ex-MOD 110, and I'm trying to decide whether to go 1.2 or 1.4 when I do the swap. I've got one of each.

So let's say you are heading west on I-70. You can still use 5th once you're past west of Vail Pass, right? Is it bad enough that you'd consider changing to the 1.4 ratio?

Which LT77 are you using and do you have a 5 door?
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  #16  
Old May 29th, 2011, 12:39 PM
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John B.
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Quote:
Originally Posted by meatblanket View Post
You can still use 5th once you're past west of Vail Pass...
Needing to shift down on a hill should not really be the reasoning for lower gearing. I see two criteria.

1) Can you pull away in 1st on "normal" hills without excessive clutch slippage?

2) Is 5th usable on flat terrain.

Shifting down is the reason you were given 5 gears.
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  #17  
Old May 29th, 2011, 01:27 PM
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Tony Sims
1984 110
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Assuming stock 31" tires, a 1.22 case will drop the final drive ratio in 5th from 3.84:1 to 3.33:1, netting about a 425 rpm reduction for equal road speed.
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  #18  
Old May 29th, 2011, 01:29 PM
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Jamie Austin
1992 110 Td5 CSW & 1989 MB G-Wagen
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In my 110, with 255/85 tyres and 1.2:1 t/box, on a steep hillstart i'll just slip into low range 2nd, get up some speed and then pop into high range. makes for an easier life on the clutch.

At the other end of the scale, she'll pull 110mph with enough room! (although it is a tweeked Td5....not a Tdi)
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  #19  
Old May 29th, 2011, 02:33 PM
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Quote:
Originally Posted by Red90

Turn up the off boost fueling. It goes a long way to reducing turbo lag and help with starting off in 1st.
Isn't there a write up somewhere about that?
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  #20  
Old May 29th, 2011, 02:51 PM
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John B.
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http://forums.lr4x4.com/index.php?showtopic=31

Try turning the "smoke" screw clockwise (the screw on the top of the boost diaphragm. Turn in 1/2 a turn, take for a drive, take off full throttle at low rpm and look at smoke level before the turbo kicks in. Adjust to a level you are comfortable with... This does not change the maximum fueling on boost so there is no danger of high EGTs.

Here is the "original" page, which still has photos... http://dodgeram.org/tech/dsl/more_power/Power_ve.htm
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