Hey all, Been a while since I've been on here. Over the winter I decided to drop my transfer case as it was making a humming/whining noise when I'd drive. Figured it was a bearing going out. When I bout my Disco I bought a used 04 transfer case with the diff lock. I should've rebuilt it before I swapped it, but I was so excited. It drove great for about a year and a half. Had a very minor leak that looked like it was coming from once of the covers. I could never narrow it down. Took my son and I on some great trails in the south. Even with the whining transfer case that started about a year after the swap.
Before Christmas I decided it was a good time to go ahead and pull it into the garage and drop the xfer case. When I drained the flud it was kind of a rusty color (brownish). Pulling it was fairly straight-forward. It little more difficult the older I get. Sure wish I had a lift. Took it down lower garage 'shop' and started tearing into it. Wasn't looking good. the entire gear set was rusting.

Not sure how I got any water in there. Everything had a nice crust on it, that you could wipe with a finger and really feel the grit. I thought about cleaning the parts up and throwing them in and bead blast everything to clean it all up, but luckily I had a spare transfer case I picked up a few years ago for cheap. It was from an older Disco 2. I made the decision to tear that one apart and swap out the insides into the 04 case. I ordered the rebuild kit from Ashcroft along with some upgraded internals right after Christmas. I was surprised... it only took about a week and a half for the box to shop up. Assembly was pretty straight forward. First time rebuilding a transfer case I really enjoyed it. Got it all back together.


Installed in the Disco. The interior is still in pieces, but I was able to take it for a test drive and everything works great! I have a lot of brittle plastic that I'm repairing currently while I get the interior put back together. I love working on my Disco.
For anybody thinking about trying this, I would tell you. It's not that difficult to do. That being said. I have a casing, a parking brake assembly from the other Transfer case if anybody is interested. I have all the old gears if anybody is interested in cleaning them up. I'm in the Atlanta area if anybody wants them. They are free, yours for the taking. PM me if you're interested.

 

Nice job!