Drilling transfer box gear to prevent damage to transmission shaft - Defender Source
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  #1  
Old November 11th, 2014, 07:29 PM
jack SF
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jack baran
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Drilling transfer box gear to prevent damage to transmission shaft

my transmission shaft wore out because the transfer box gear is not drilled. I am having the trans rebuilt. I know I have to replace tbox gear or drill it to prevent future damage to trans shaft.
are there any plans where to drill the gear. would a gear out of a discovery tbox fit? I have a couple of tboxes from disco 2.
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  #2  
Old November 11th, 2014, 08:06 PM
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If the transmission and transfer box are already out, I would just replace the transfer box with an LT-230Q. A used one should be under $500.
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Old November 12th, 2014, 08:22 AM
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J. Michael McCaig
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I have drilled the gear...I guess because I'm cheap and wanted to use the low mileage LT230 I already had. You have to use a good drill press and I used a carbide tipped drill bit because the gear is really hard. I copied the factory pattern the way it's drilled in the later LT230 gears. I didn't drill quite as large a hole as the factory gear but so far after 30K miles it seems to be lubricating the splines just fine.
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Old November 12th, 2014, 11:37 AM
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Rather than drill, I'd take it to a machine shop that can do EDM.

In case you don't know, this process is burning a hole (or shape) through a metal by a carbon electrode while submerged in a liquid coolant. This process is very clean without putting stress on the entire part.
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Old November 12th, 2014, 11:49 AM
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Ashcroft sells the t-box gear pre-drilled. I'll bet if the output shaft stripped you have wear on the gear and it should probably be replaced as well?
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Old November 12th, 2014, 11:58 AM
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I agree. Normally both parts wear out. http://www.ashcroft-transmissions.co...nput-gear.html maybe $100 +/-....
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Old November 12th, 2014, 06:47 PM
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Charles Galpin
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Mike,

What size hole, and is it just centered on the skinny section, 90 degrees apart? I have access to a milling machine and would like to give this a try.

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Originally Posted by LRover View Post
I have drilled the gear...I guess because I'm cheap and wanted to use the low mileage LT230 I already had. You have to use a good drill press and I used a carbide tipped drill bit because the gear is really hard. I copied the factory pattern the way it's drilled in the later LT230 gears. I didn't drill quite as large a hole as the factory gear but so far after 30K miles it seems to be lubricating the splines just fine.
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Old November 12th, 2014, 09:11 PM
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BTW, I considered the oiling plate. It's only 15 but 27 shipping!
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Originally Posted by Red90 View Post
I agree. Normally both parts wear out. http://www.ashcroft-transmissions.co...nput-gear.html maybe $100 +/-....
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  #9  
Old November 13th, 2014, 03:32 PM
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J. Michael McCaig
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Yes, centered on the skinny part, 90 degrees apart. The factory holes are 5/16" if I remember right and I drilled 1/4". You shouldn't have any problem with using a milling machine as long as you have a good drill bit that will work on the hardened gear
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Old November 13th, 2014, 04:45 PM
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Charles Galpin
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Good point. I'll give drilling the holes a try first though.

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Did you check with Dassler? That is where I got mine.

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Old December 6th, 2014, 04:49 PM
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Just wanted to give an update on this. I used a 5/16" end mill and it worked fine.

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