Disco Tcase to LT77 - Defender Source
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  #1  
Old March 24th, 2011, 01:41 PM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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Disco Tcase to LT77

Well After doing some research Ive got some questions. Found a guy with a Tcase out of a


1997 Discovery I with a an automatic

If I swap over my manual linkages will it bolt up to my 200tdi and LT77? Im trying to save some $$ on fuel and move a to a 1.2 Tcase
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  #2  
Old March 24th, 2011, 02:15 PM
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I'll take your 1.4 if you wish to part with it.
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  #3  
Old March 24th, 2011, 02:31 PM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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Thanks but ill be keeping it just in case i dont like the conversion.

BUT

I did see this on craigs a few days ago...looks very clean

http://newyork.craigslist.org/fct/pts/2278471030.html
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  #4  
Old March 24th, 2011, 03:47 PM
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Jake K.
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Should bolt right up without any issues. The only issues are with the early t-box's with the short splined input....as long as it's out of a Disco1 it will work. That listing for the 1.4 box is a steal even if it needs a "go thru"! Somebody snag it before my wallet is $250 lighter!
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  #5  
Old March 24th, 2011, 04:05 PM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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nice, thanks


Anyone have a 200tdi and a 1.2 case? My truck with the new turbo has some cagones and can climb hill sin 4th and 5th with out too much stress. Will this totally chop its balls off?

im on ~32in rolling diameter tires
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  #6  
Old March 24th, 2011, 06:58 PM
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Quote:
Originally Posted by Naplm00 View Post
nice, thanks


Anyone have a 200tdi and a 1.2 case? My truck with the new turbo has some cagones and can climb hill sin 4th and 5th with out too much stress. Will this totally chop its balls off?

im on ~32in rolling diameter tires
Yes 110 pickup. on 255.85.16's (33.25) No problem's @ all my brother loves it. Gearing is 15% taller than your 1.4.
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  #7  
Old March 24th, 2011, 09:51 PM
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Only down side is the lack of pulling power in first. From experience if you have to start on a hill you'll have no enough power in comparison to the 1.4 t-case. It makes it harder if you're pulling a load or a trailer. Think of it. I try all of them with my 200 tdi (1.2 1.4 1.6) and 1.4 is the best one.. I guess if one could have higher gearing only on fifth it would be good on highways but, hey, life isn't perfect!
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  #8  
Old March 24th, 2011, 10:54 PM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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This might be a good thing for me. My first gear is so short and low it is useless. I only use it on hills from 1to5 mph. Is this the norm?
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  #9  
Old March 25th, 2011, 07:23 AM
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Jeff Labbé
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Are you sure you don't have a 1.6 t-case? When I had this set-up I also found the 1st gear too short. What's your top speed without over revving the engine? 70-75mph? Or more 55-60mph?
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  #10  
Old March 25th, 2011, 07:29 AM
Naplm00
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Matthew
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I assumed it was a 1.4, I don't like bringing it over an indicated 60...the cab gets too loud and out feels like I'm stressing it. I'll for the serial this morning.
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  #11  
Old March 25th, 2011, 07:42 AM
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While you're swapping, replace the LT230 input gear with the cross drilled version. It's an easy job, not expensive, and the cross drilled input gear has both the cross drilling to improve lubrication, and longer splines for a stronger point of transfer from the transmission output shaft. Hopefully you will not need to replace the output shaft on the LT77, but it is a common thing to wear out on early trucks. I bought a 1.2 case and LT77 out of a Disco with about 80k miles, and the splines on the LT77 output shaft were worn to less than 1mm thick.
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  #12  
Old March 25th, 2011, 09:13 AM
Naplm00
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1983 110 200tdi 3 door soft top
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Quote:
Originally Posted by CDNRover View Post
Are you sure you don't have a 1.6 t-case? When I had this set-up I also found the 1st gear too short. What's your top speed without over revving the engine? 70-75mph? Or more 55-60mph?


DING DING DING we have a winner!


Yea so I ASSumed wrong. I took the time and scraped the crap from the side of the Tcase and called ashcroft

12D001888A

Its a veerrrry early 1.667 Ratio Roller bearing tcase.




So most definitely moving to a 1.2 disco taper bearing case will prove to quiet it down and give me better mileage, but I will have to re learn how to drive it..and I will loose alot of "uuumph"
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  #13  
Old March 25th, 2011, 09:24 AM
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William Skidmore
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What about a Roverdrive? I know they make them for Defenders.
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  #14  
Old March 25th, 2011, 09:25 AM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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Quote:
Originally Posted by airbornrover View Post
What about a Roverdrive? I know they make them for Defenders.
yea was originally thinking this but, they are $1800 US now..and a used Tcase is 200-300
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  #15  
Old March 25th, 2011, 09:46 AM
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William Skidmore
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Economics. Fair enough.
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  #16  
Old March 25th, 2011, 10:15 AM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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affirmative sir
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  #17  
Old March 25th, 2011, 07:35 PM
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Jeff Labbé
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If it's an early 1.6 t-case then you shouldn't have a cross drilled input gear. I'm afraid that your shaft will be worn by now. Before going a route or another I would take the input gear out to check the shaft first.. Don't want to spend money for and overdrive or anything else if the shaft is worn out...
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  #18  
Old March 25th, 2011, 11:23 PM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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Yea I'm thinking it should be replaced when I do the tcase. What is a source for the input shaft?
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  #19  
Old March 26th, 2011, 01:29 AM
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John B.
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There are two things you need to do.

1) Remove the shift lock out solenoid.

2) Grind a flat and drill and tap for the hand brake cable mounts on the back.
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  #20  
Old March 26th, 2011, 05:54 AM
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Tony Sims
1984 110
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Quote:
Originally Posted by Naplm00 View Post
Yea I'm thinking it should be replaced when I do the tcase. What is a source for the input shaft?
You can buy it from any LR dealer. Ashcroft's site has the details on part numbers and serial numbers to determine which input gear you need for your particular box.
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[appropriated from Ren Ching] Most faults can usually be traced to the badge on the grill.
Quote:
Originally Posted by chris snell
This is straight out of the Manual for Build Builders.
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