[lt77 gearbox strip]

hi can anybody help me out with any info regarding stripping an lt77 gearbox? i am wanting to swap the output shaft on a box i have bought with worn splines, with a good one i have in another box. a link with photo,s would be usefull if anybody knows one. steve.

[lt77 gearbox strip]

hi can anyone put me onto a good link for stripping an lt77 gearbox with some good photos showing various steps ? i have found one for the r380 but cannot seem to find much for the earlier box . i have just bought a box with some wear on the output shaft splines and have another scrap box with good splines so want to swap the output shafts . i have started stripping the scrap box but don,t seem to be able to remove the thin section of the box between the aluminium section and the main casting . can anyone give me any advice . steve.

[glow plug light]

Mine does this occasionally, (it did it last night). The light is controlled by one set of contacts within the relay and the power to the plug goes through a different set. On mine the plugs work fine regardless of the light operation, to fix the light I just pull the connector off and then re-connect it which cleans the corrosion on the connection and the light starts working again. When I first got mine the relay didn't work at all and when I investigated I found that all the connections had gone green and loose with corrosion, so I cleaned them all up and squashed the crimps a little to make them tighter and since then the plugs have worked every time, just sometimes the light doesn't.

Pete.

in case it helps anyone the white/ brown wire to the timer /relay is the earth from the dash warning light . if u suspect the bulb has gone , with the ignition turned on and this wire earthed out the bulb should be lit . this is easier than taking out the instrument panel to find out if the bulb has blown ! but if it has then its to come out anyway.

just converted my v8 to tdi when i wired in the heater relay the warning light wouldn,t light . this is because the v8 loom doesn,t have a wire from the warning light to the heater relay . as i had a spare loom to butcher i removed a connecter from the instrument multi plug and put it into my v8 multi plug (i think it was terminal 5 on the plug , this gave me the wire i needed to make the warning light come on ) connect this to the white /brown wire on the relay. connect the relay white wire to ignition live i used the original coil feed wire which i have also used for the fuel shut off. connect the relay white/ red wire to the white /red on the starter motor . i had 2 white/reds in a connecter of there own when i traced them thru the harness they both join together and go to the starter , i split them and used one of these . u could run a wire direct to the starter but my way looks a lot neater. the black wire from the relay just needs to go to an earth point . the thick brown to battery positive and the thick black/yellow to the heater plugs . it all now works as it should and the warning light comes on when the key is turned stays on for around 5 seconds then goes out the relay is still on for around another 10 seconds before switching off. hope this helps someone out . of corse u can make the heaters work without the warning lamp but i wanted mine to work and be a tidy job when finished. no ugly wiring under the bonnet . nothing to give it away that its not a factory fitted tdi . steve.

[heater blower...]

Do you notice whether the lights dim or not when you put blower switch on when the blower doesn't work?

My blower stopped working all together but when the lights were on and I put the switch to position 3 the lights dimed (motor drawing charge) but the blower refused to work. Having mistakenly left it like this for a minute or two driving home the other night I got a nice smell of burning!

Anyway took dash out and direct wired the motor once I had split the blower housing (thats fun) to find blower works ok. bearings are a little naffed but it works ok. Here is the switch

The spade connector to the switch was all melted Anyway, what I found was that the blower motor housing has rusted causing it to sit off centre in the blower housing this caused the hamster wheel to bind on the casing and stop spinning - motor still drawing charge and overloading the switch because it couldn't spin probably cause of switch melt down.

I have resoldered the switch and it now works. I cleaned all rust off the blower and reinstalled it in the blower housing only to find it is now a little loose and does the same thing - swims about causing the hamster wheel to catch on the blower housing and stop it spinning. I am going to now try and wedge it in position. Took pictures of it if your interested?

I don't know if any of that helps but as cipx2 says you might need to crack the heater out

DaveJ

hi dave whats involved with removing the dash to get to swap the heater matrix . how many fixings are there n how long a job is it ? i snapped the end off the heater matrix whilst swapping my v8 to tdi engine didn,t realise till i started the engine and couldn,t stop the hose connection to the heater from dripping then i found out i had cracked the fitting . must have lowered the engine onto it . had to bypass the heater but need to get it fixed as i,m freezin mi nuts off! my brother has to relace his heater as the fan has packed in on his . both are 200 disco,s . cheers steve.

[R380 direct replacement for an LT77?]

I was assuming that you had/are getting the complete box. You don't need the transfer box you can just swap in the one off the LT77.

The R380 is considered the better of the two boxes anyway.

hi andy , so will the r380 box with the 300tdi bell housing bolt straight on to the 200tdi engine or do u use the lt77 bell housing on the r380 box ? do u , or anybody reading this, have any information of anybody thats used a disco gearbox in a defender? i know the engine will be closer to the front of the vehicle but would like to know where the main gearstick would end up and if its still comfortable to change gear ? steve.

[disco gearbox into a 90 ?]

hi , wonder if anyone can help me out i,ve been reading the item about fitting disco 200tdi engine into a 90 by les henson and how to fabricate a front pipe . after this someone has posted a picture with a disco cast front pipe and les comments about how much room there is around the bulk head. this leads me to believe the disco engine will fit into the engine bay useing the disco box and bell houseing but the engine will be sat further forward than when useing a 90 box . i know the disco transfer box is different gearing and that the main gearstick is in a different position but i would like to hear from anybody who can tell me if this conversion is posible . better still any photos showing where the disco gearlever ends up in the 90 cab? would the different gearing really be a problem ? the discovery doesn,t seem to have a problem with this gearing. any photos showing where this setup would sit in the 90 engine bay would also be an help , any problems with clearence or with engine components hitting axles etc. any info at all would be much appreciated . cheers turbomangler.