Dual transfer cases - LT230 - Defender Source
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  #1  
Old March 22nd, 2016, 10:29 PM
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Dual transfer cases - LT230

I originally dreamed this up 5+ years ago when NV4500 to LT230 adapters were few and far between, and one of my 4wheeling buddies has a Unimog, so I had serious shifter and gearing envy.

The idea was to use the reduction box out of an NP203 American transfer case, which came in all kinds of applications and bolts up to an NV4500 or just about any other american trans (4L65, 4L80, TH400, etc etc) without any custom work. There are input gears in just about every common spline from 23 spline Dodge to 27 GM, 32 GM, 31 Ford etc. So it becomes sort of like a universal adapter.

The case gives you an additional selectable gear reduction between the trans and the LT230 T-case, so you would have high, low (3.32) and super low (6.64). The best part is it gives you an extra shifter to play with.

The input gear for the LT230 transfer case was EDMed by Buck (Buckon37s) out to 32 spline GM. The output shaft was machined and re-splined in house, and the adapter plate was milled out of a great big hunk of aluminum. The only work I did not do myself was the EDM work, and plating the bolts.

The LT230 in question is a really early (1983) version from a Range Rover, LT230R 1.003 gear ratio.

The addition of the box adds 6.875" to the powertrain, but it also acts as an adapter between an American trans and the LT230. I don't think this would fit in a 90 but it fits into a 110 pretty easily. With the NV4500, the overall length from bellhousing to the LT230 mounting flange is 32.875, which is 8.3 inches longer than an R380 from a Defender application.

The gearing is kind of crazy. 5.61 1st in the NV4500 X 2 X 3.32 X 4.10 axle ratio is 152 to 1... And it's a very stout unit. But what really matters is I get another shifter!
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JL
1994 Defender 110 300TDI 3 door
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  #2  
Old March 22nd, 2016, 10:36 PM
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Dan Prasada-Rao
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Nice!
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  #3  
Old March 22nd, 2016, 10:39 PM
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What's it going behind ? 6b ?
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  #4  
Old March 22nd, 2016, 10:43 PM
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Don Bunnell
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That is really slick JL!

That finish is incredible too!
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  #5  
Old March 22nd, 2016, 11:08 PM
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Quote:
Originally Posted by Uncle Douglas View Post
What's it going behind ? 6b ?
6BT (T = turbo)
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1994 Defender 110 300TDI 3 door
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Diesel-swapped 1994 80 series Land-cruiser
And a difflocked 4wd turbodiesel Lambo
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  #6  
Old March 22nd, 2016, 11:12 PM
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Don Bunnell
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Quote:
Originally Posted by oilburner View Post
6BT (T = turbo)
6BT with that low low will be able to climb walls
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  #7  
Old March 22nd, 2016, 11:41 PM
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You weren't kidding about the plating. Looking good!
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  #8  
Old March 22nd, 2016, 11:52 PM
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Quote:
Originally Posted by don View Post
That is really slick JL!

That finish is incredible too!
Would turn 37's without an issue, I could probably assist in your acquisition of a 6bt should you decide to go down that road.
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  #9  
Old March 23rd, 2016, 12:07 AM
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Don Bunnell
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Originally Posted by JohnsD90 View Post
Would turn 37's without an issue, I could probably assist in your acquisition of a 6bt should you decide to go down that road.
I'm sure 37's wouldn't be an issue!

Going new IP with bigger plungers and a bigger turbo on the OM617 for now but thanks for he offer
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  #10  
Old March 23rd, 2016, 06:11 AM
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Jamie Austin
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Wow, that's sweet.


One can never have too many shifters! It'll be like a 'mog with the 3x8 cascade box.
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  #11  
Old March 23rd, 2016, 09:21 AM
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JL has had his 6bt for quite some time and already had it in a 109.
He had the 109 out @ Moab climbing slickrock etc.
What he's building now is what I want to see.
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  #12  
Old March 23rd, 2016, 09:33 AM
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The plating is zinc passivate, mostly for corrosion resistance...

With the 6BT the gearing is probably overkill, but, shifters!!!
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Diesel-swapped 1994 80 series Land-cruiser
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  #13  
Old March 23rd, 2016, 09:36 AM
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quit teasing post pictures of what you are putting it in
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  #14  
Old March 23rd, 2016, 09:43 AM
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Quote:
Originally Posted by oilburner View Post
The plating is zinc chromate, mostly for corrosion resistance...
Fixed it

resistant, yes, proof, no.

Pretty damn awesome doubler box I gotta say.
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  #15  
Old March 23rd, 2016, 10:01 AM
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This work is over the top.

I am wondering if it is possible to use this in a Land Rover gearbox configuration for use with small diesel engines, like the Land Rover TDI.
So if this application were used with a 300TDI for example.
The extra length might be taken up by a stumpy R380 that would space the 300TDI in or close to the stock location.
Perhaps all you would need would be a short adapter between the stumpy and the reduction box.
I know the original goal was probably to adapt the whole assembly to a main stream gearbox and thus an easy adaptation to any number of more powerful engines, but what about a "sandwich concept" pieced into a Rover drive train?
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  #16  
Old March 23rd, 2016, 10:11 AM
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Nice...
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  #17  
Old March 23rd, 2016, 01:16 PM
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I need to give credit to another guy, I just found out Tony - 16KPSI - originally ran the run of EDM'd gears input gears for Buck! He's using one in his own 110 I believe. Thanks Tony, it worked slick. He's also putting a 6BT in his 110. Obviously a smart guy.

As far as using this behind an R380, it would be tough, the idea behind the adaptation was to be able to bolt up to a standard American trans, and they use a different output arrangement than a Rover trans.

For the R380, a custom output shaft for the trans would be needed, which is a lot of work. I think the Ashcroft Underdrive is probably the best option if you want to retain stock rover stuff...

Doug - I will start a build thread eventually, right now all I have is a large pile of parts, I literally am just building all the parts one by one, nothing much to look at until I start assembling it...
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1994 Defender 110 300TDI 3 door
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Diesel-swapped 1994 80 series Land-cruiser
And a difflocked 4wd turbodiesel Lambo
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  #18  
Old March 23rd, 2016, 08:37 PM
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I finally have a use for this
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  #19  
Old March 23rd, 2016, 09:52 PM
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I finally have a use for this
that right there is funny
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  #20  
Old March 24th, 2016, 01:45 PM
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Very nice setup. The 203 is a great unit, affordable and everywhere. I'm currently setting up an NV4500/NP203 for my Cruiser, looking forwards to your crossmember and shifter designs, I'm not quite at that stage yet and could use all the inspiration I could get.
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