Hi there: I'm planning to do a complete rebuild of the LT230 Transfer box on my 1998 Disco 1.
Question I'd like to put forth: can I drop-down the transfer box on its own WITHOUT droping down the main gearbox ? I would rather take down only the transfer box for repair, leaving the main gearbox in place. Does anybody know if on a Disco 1 this can be done ?
Thank you for any reply or hel on this issue.

 

Welcome aboard.

Recommend you do a search for and download the available manuals it aide in your mx activities.

Have never done this myself and others may give their 2 cents.

 

Hi number9. I have the LT230Q transfer box Overhaul Manual. But I'd like to know if anybody with a Disco I has taken down the transfer box on its own leaving the main box in place. Manual gears..
Thanks for the PDF anyway !!

 

FYI,

PDF is from D1 Workshop Manual for removal procedure and does not differentiate between auto/manual procedures. There is no mention of removing main gear/trans. Answer to question likely lays there.

Warm & fuzzy reassurances may follow but manual gearboxes aren't as common in the US.

......

 

Not sure about being able to drop without removing tranny because I have an automatic, however I don't see why not. Based on the LT230 having a shifter directly bolted on and coming through the floor board it should line up in the same spots on the frame. Having said that, unbolt the shifter from up top, unbolt driveshafts, disconnect all electrical, unbolt mounts, support tranny, slide off towards the back and brace for impact (it's heavy). Any questions you can message me. I just rebuilt mine but with the body off the frame

 

Two things I'd suggest for removing the transfer case, remove the drum brake assembly and unbolt the transmission from its frame mount. That way you'll have more room to slide the transfer case of the transmission coupler. With the drum brake on you run into clearance issues with the floor. So, between lowering the transmission and transfer case thanks to unbolting the frame mounts and removing the drum brake, you'll have plenty of room to remove the transfer case from the transmission regardless of whether it's an auto or 5 speed.

 

I believe it's easier to drop both as a unit and then separate them. I also believe it's easier to swap a used LT230 in there instead of rebuilding it. I haven't done it both ways so I wouldn't know for sure, but I blew up an LT230 and just swapped another one in.

 

The problem with swapping LT230 is the price asked for a second hand one at my place... I looked around and was given prices like €580 (£815) for a used non repaired and non checked one... ! Too expensive !! I've already got a full kit with all the neccesary bits and pieces to do a rebuild. Just need the time and the right moment to get the job under way...

 

I agree that it's easier to buy a good, used LT230 as an alternative to rebuilding.

I do not agree that it is easier to remove the both the transmission and transfer case (regardless of whether it's an automatic or a five speed) than it is to remove just the transfer case. What purpose would be served removing the two units? You'll still have to separate them once they've been removed. Unless you plans include a new clutch for the five speed, leave it alone. Six bolts hold the back of the transmission to the front of the transfer case. You have the bolts holding the transfer case and transmission to their respective frame rails. Beyond that you have what needs to be removed from the inside of the truck. It's really not a terribly complicated job. Why create more work by also removing a transmission you have no need to work on?

 

I agree with Paul Grant. Also, if tight on space, remove the back access cover to the t-case and you can take the input shaft bolt out so instead of pulling it backwards 6-8 inches, you are only pulling 3-4. I have pictures somewhere for reference.

My two cents, swapping may be easier and more costly, but rebuild was not hard at all. I did it without a manual.