When I changed the driveline fluids to 85w140, I had some metal bits attached to the tcase drain plug. The fluid that came out was pretty thin and had obviously been in there for a good while. I should mention that it has seemed since we purchased it in October that there was some driveline binding going on. It doesn't feel like the case is fully locked, but there is no question it binds in tight(ish) turns on pavement, although I get wheel slip between the axles on slippery surfaces where I can feel the tires with less traction spinning at one end or the other. Yesterday it starting making a gear rattle when coasting - only when completely off the gas - that changes to a much faster rattle in low range. I can actually feel the vibration from the tcase through the H-L selector lever. Doesn't make any noise when in reverse or when the case is in neutral. So it seems like something on the input-side of the case. I'm figuring it's time to replace the case. I'm a fair mechanic, can the case be changed out without a lift? Will a DII case work (I think it should from what I've read and they seem to be much easier to come across)? We bought this Disco right, and everything else seems to be great at 118k, so as long as I don't have to pay someone to swap the tcase, I'm happy.

 

Along with this, where's the best place to find a Transfer case? There seem to be some on Ebay, but buying used parts like this on Ebay makes me a little nervous.

 

First, where are you located? A transfer case without the brake drum assembly weighs a little over 100 pounds when packed for shipment. So, depending on where you are, the cost of shipping can be a prime determinant in your purchase.

Second, what year is your DI? I ask this because if you try to mount an LT230 from a '96-'99 DI on an earlier DI you will need to get a transmission coupler as well.

Third, you really can't use the entire LT230 from a DII. So, unless you want to involve yourself in a lot of unnecessary bs, stick with DI transfer case.

Finally, there are a number of reputable sellers on eBay who specialize in Land Rover parts. You just have to be sure you are buying from someone who really knows these trucks as opposed to some random junkyard. I can make recommendations should you like.

I also have a couple of LT230's from DI's on hand should you be interested.
Cheers,
Paul Grant
Classic Rovers

 

Thank You, Paul! Our's is a '96. We are located in Wyoming, so chances are it will be coming from a long distance no matter where it's from. Can the Tcase be replaced without a lift? I can get it up on ramps if that helps. Also, can anyone recommend a good repair manual? The Haynes books are the best for BMWs, are their Rover ones useful?

 

You should go to this page and download the RAVE which is the online repair manual for all Land Rovers. There's a lot of info there but once you've sifted through you'll get the hang of it and find all the help you should need.

land rover service factory manual RAVE download land rover resource, service manual, workshop factory manual, download, rave, vehicles including discovery, series, defender, range rover, freelander, LR3, Handbooks, Catalog, Catalogue, Land Rover Inte

You can do the removal without a lift. You will need a jack and jack stands.

I would recommend, if you're doing this on your own to remove the transmission brake assembly at the back end of the transfer case. It weighs about 45 pounds and can get in the way as you try to back the transfer case off the transmission coupler coming out of the back of the transmission. The brake drum is held in place with a single screw and the backing plate with shoes is held to the output assembly with four 15mm bolts. Get it out of the way and I think the overall job is a lot easier.

 

Paul, what's the coupler you're speaking of?
I've never compared an early auto to late auto, but I've used a '95 LT230 from a 5-speed on a '97 ZF without any issue (other than the speedometer being off).

As for the OP, I highly recommend the LT230 jack adaptor (specs in the manual) for R&R, it makes life a lot easier.

 

The transmission coupler (FTC5090) extends out the back of the rear output assembly of the transmission, into the transfer case. In 1996 Land Rover redesigned the coupler with longer splines. All LT230's from that point were designed to work with the longer splined coupler. So, you can put an earlier ('94-'95) case on a later ZF ('96-'99) with no issues. However, should you try to install a later LT230 on an earlier ZF with the shorter splined coupler the transfer case will not seat properly.

This issue became apparent when everyone with a busted BW wanted to move into an LT230. Anyone looking to make this change while using a later LT230 (the Q was particularly desireable) needed the longer splined coupler.

These days, fewer people are still doing the conversion to the LT230 so the demand for the coupler has fallen off a bit. Nevertheless, if you want to use a newer LT230 with the older ZF you need this part.

Land Rover Discovery Series 1 1996 99 Transmission Transfer Case Coupler FTC5090 | eBay

 

Now the case makes noise whenever the Disco is moving. Luckily Paul is shipping me a replacement, all it has to do is make it into the garage!