1965 Posted March 4, 2006 Share Posted March 4, 2006 HELLO , I NEED HELP . I'VE JUST REPLACED MY 2.5NA WITH A 200TDI AND REALISED THE GEARING IS A LITTLE LOWER THAN IT SHOULD BE . I STILL HAVE THE DISO BOX , SO AM I CORRECT IN THINKING THAT I SHOULD EITHER CHANGE THE TRANSFER BOX OVER OR SWAP THE BELL HOUSING AND INPUT SHAFT FROM THE NA BOX TO THE DISCO BOX, WOULD THIS SOLVE THE PROBLEM ? BEARING IN MIND I HAVE NEVER WORKED ON GEARBOXES I'M NOT SURE HOW TO DO EITHER ONE , DOE'S ANYONE KNOW WHICH WOULD BE THE BEST OPTION AND MORE IMPORTANT HOW TO DO IT . ANY HELP OR ADVISE WOULD BE GREATLY WELCOME Quote Link to comment Share on other sites More sharing options...
minivin Posted March 4, 2006 Share Posted March 4, 2006 hi there and welcome to the forum! The input pinion ratio is the same between both of the gearboxes so this won't solve the problem, there are slight gear ratio changes between the gears (except fourth, which is always 1:1), so it looks like a transfer case swap. Quote Link to comment Share on other sites More sharing options...
western Posted March 4, 2006 Share Posted March 4, 2006 Swapping the High range gears in the Transfer box should solve the problem, Please use lowercase text Quote Link to comment Share on other sites More sharing options...
1965 Posted March 4, 2006 Author Share Posted March 4, 2006 THANKS FOR THE WELCOME , DO THE TRANSFER CASES JUST UNBOLT AND SLIDE OFF ( HE SAY HOPEFULLY ) OR IS THERE MORE TO IT THAN THAT . GEARBOXES ARE SCARRY THINGS I HAVE IMAGES OF SPRINGS AND BALLBEARING FLYING EVERYWHERE . BY THE WAY , I PLAN TO CHANGE BOTH AXLES OVER WHEN THE WEATHER CALMS DOWN A BIT SO THAT SHOULD HELP . Quote Link to comment Share on other sites More sharing options...
minivin Posted March 4, 2006 Share Posted March 4, 2006 not sure on transfer case removal as I've never had to do it. But gearbox-wise there is little to worry about an LT77, there's more in the way of springs and balls in the earlier Series gearbox gearchange mechanism. The only spring that I can think of at the moment is for the gearchange detent plunger, which 3 out of 4 varients of LT77 that I have stripped (SD1, LDV400, Disco LT77S and Def90 LT77), only the very early Suffix C resulted in the ball falling out and dissappearing under the work bench Biggest problem is the removal of the nut for the layshaft fifth gear, and generally pulling all the gears off the mainshaft which are a press-fit. All just takes time and a manual, or as I did brought a scrap box and practiced with that Quote Link to comment Share on other sites More sharing options...
1965 Posted March 4, 2006 Author Share Posted March 4, 2006 thanks for the help , i'll have to check whats involved . it would be simpler to just put the disco box in but i would need to change the bellhousing , it's longer apparently and would move the gearbox to far back. this would also mean changing the input shaft . Quote Link to comment Share on other sites More sharing options...
Mark90 Posted March 5, 2006 Share Posted March 5, 2006 There's no need to strip the gearbox, just swap the transfer box over, yes they unbolt and slide off the back of the gearbox. Quote Link to comment Share on other sites More sharing options...
Matt Neale Posted March 5, 2006 Share Posted March 5, 2006 There's no need to strip the gearbox, just swap the transfer box over, yes they unbolt and slide off the back of the gearbox. Yep - and don't bother swapping axles over as the diff ratios are identical. Matt Quote Link to comment Share on other sites More sharing options...
1965 Posted March 5, 2006 Author Share Posted March 5, 2006 thanks for the response , just the answers im looking for . axle change was more to do with disc brakes than anything else , but i did'nt know the ratios were the same . is it poss to convert my drums to disc without changing axles. Quote Link to comment Share on other sites More sharing options...
JST Posted March 5, 2006 Share Posted March 5, 2006 whats the std n/a t box 1.6? and the disco will be 1.2, so may find it a little tall, depending on what tyres your running. 1.4 isn normally ideal if the n/a is 1.4 then forget the above as you have tried it! Quote Link to comment Share on other sites More sharing options...
western Posted March 5, 2006 Share Posted March 5, 2006 is it poss to convert my drums to disc without changing axles. Yes, strip each down until the stub axles are fully visible, if these are identical then just fit the disc brake bits to the existing axle on your vehicle, if there not identical you'll have to swap the stub axles as well. Quote Link to comment Share on other sites More sharing options...
1965 Posted March 5, 2006 Author Share Posted March 5, 2006 ok , thanks for the help everybody , your all a god send , i'll check it out now i've got more info Quote Link to comment Share on other sites More sharing options...
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