LT77 Lay shaft swap between suffixes - Defender Source
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  #1  
Old August 18th, 2010, 12:24 PM
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shawn maffei
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Unhappy LT77 Lay shaft swap between suffixes

OK, here goes...Have an LT77 out of a 200TDI D-90, ser #50A0111258D. It has a chewed up reverse gear and reverse segment on the lay shaft. I have it all apart and just received my Ashcroft master rebuild kit. I have recently acquired a second LT77 out of a V8 Ser#61A0178753H. I also have this unit apart in order to pull the reverse gear and lay shaft out and put them in my d suffix unit. However...the layshaft gearing looks a bit sturdier or thicker on the reverse section and one other section. My question is, can I still use this lay shaft or am I gonna have to order a new one from ashcroft. Also, am I able to just swap bell housings and main shafts and use the LT77 out of the V8 instead. I know there are quite a few folks on here who are very knowledgeable so I will sit back and wait for the enlightenment. Thanks a million in advance.
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  #2  
Old August 18th, 2010, 01:12 PM
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Dave McHenry
1984 Landrover 90 CSW
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call Rob from southwest rovers at 1-505-872-7818
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  #3  
Old August 22nd, 2010, 01:15 AM
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shawn maffei
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Called Rob...bad news "H" suffix lay shaft bearings are bigger so can't use that. Thanks for the info.
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  #4  
Old August 22nd, 2010, 01:39 AM
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John B.
1991 Defender 90, 200TDI
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Personally, I would not waste your time rebuilding a "D" to live behind a 200TDI. They are meant to have an "H". The TDI will just kill the layshaft bearings again. You want "G" or "H" only.
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  #5  
Old August 22nd, 2010, 05:33 AM
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evilfij
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Can you put the d input and main shaft on the h? I know rob built a nas 110 lt77 to run behind a 200tdi I am just not sure how.
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  #6  
Old August 22nd, 2010, 09:52 AM
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Chris Baldewin
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On mine he replaced the pinyon shaft with one specific for the 2.5, 2.5td and 200 tdi and then rebuilt as normal. Use the bell housing from the original trans. The only problem with V8 trans is 1st and 2nd aren't as low as a 200 tdi specific trans.
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  #7  
Old August 23rd, 2010, 01:37 PM
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shawn maffei
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I would rather use the "H" suffix unit but I was concerned about the same issue that Baldewin brings up...gear size due to it being from a V8. The H unit is in pretty good shape if you discount the fact that the main shaft splines are sh*t. I already have a master rebuild kit for the "D" from Ashcroft so I figure to complete that rebuild with a new lay shaft and reverse gear (on order) put it behind the 2.5TD still in the 90 and then maybe get hold of an R380 to put behind the 200TDi after that rebuild is finished. Wow...and the rework of the truck has just begun!
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Old August 23rd, 2010, 02:30 PM
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Here are the gear ratios for comparison.

http://www.expeditionlandrover.info/gear_ratio.htm

You will notice that the V8 LT77 has nearly identical gear ratios to the 300tdi R380. Not enough to make much of a difference with a 200tdi, with a 2.5/2.25 NA or P I would probably want the early box.

Ron
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  #9  
Old August 23rd, 2010, 03:11 PM
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shawn maffei
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Thanks for the link Ron. I would offer to sell this H suffix back to ya but I have it in a thousand pieces. ROFL
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  #10  
Old August 23rd, 2010, 03:14 PM
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I will give you your money back even in pieces. I am good like that.

Ron
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