LT77 Gear Box & LT230 Transfer Box Switch - No Lift

Tbaumer

Technical Excellence Contributor
Finally have some time to switch my failing gear box. Watched a couple videos & here we go!

Removed floors, tunnel & cross member.

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Removed front & rear drive shafts, parking brake, slave cylinder, speedo cable, reverse switch wire, exhaust pipe, etc.

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Tbaumer

Technical Excellence Contributor
In order to get clearance, the gear lever housings needed removed - a bit nasty inside.
Winched the front wheels up on some ramps (probably should've done this first), chocked the rear wheels.
Added a strap to hold the engine in place when removing the rear support mounts. Removed the bell housing nuts (& one bolt), used a motorcycle lift to slowly separate & lower the offending set. On those wooden blocks, it looks sketchier than it is. If I make a habit of this I'll have to fabricate a real transmission lift mount. So far so good!

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Tbaumer

Technical Excellence Contributor
So here we have the old & the intended. Definitely need a new bearing, but the fork looks good. Happen to have a new bearing 🙂 (my doomsday prepper mentality pays off)!

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Tbaumer

Technical Excellence Contributor
Interesting differences in the two set ups - The old "G" suffix has 13mm bolts with washers all around, a smaller magnet drain bolt & unusual mounts, while the "H" has 10mm wide base bolts, thinner linkage rods & a larger 1/2" insert style magnet drain plug. Here are some comparison pics -

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A little background on the replacement - It was purchased along with a 200tdi shortly after I got my 110, but the set had cut hoses & wires, bent pulley, missing parts & I didn't trust anything that showed up in the crate from the UK (looked like it all sat in a field for years). Pressure washed & let it sit while I looked for another complete set, so while it looks good from the outside, it is in unknown condition inside. UD sold me the current complete set up that I have been running. If I were a "real" mechanic I would open it all up & inspect, but instead, plan on putting in new fluids, driving it & flushing any crud out.
 

Tbaumer

Technical Excellence Contributor
I have a new fork in a clutch kit (that's why I had the bearing). Its a standard Bearmach kit, so not heavy duty, but I'll put the new fork in.
 

Tbaumer

Technical Excellence Contributor
Cleaned up the nasty. Assuming I need to grease this up good before putting the towers back on.

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Tbaumer

Technical Excellence Contributor
It would be quick & easy to upgrade the fork! Except, it's bolted up to the engine now :(...

Remove that setscrew and retorqe it with some red threadlock
Will do.

Back in place. Mounts on.
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I couldn't figure out why my speedometer cable wouldn't go into the sender. I removed an electronic adaptor that used a smaller diameter square hole. Switched out the sender with the one from the old.

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Noticing a bunch of little changes between these boxes.
 

Tbaumer

Technical Excellence Contributor
Only snag I had was letting the transfer box lever fall to the rear when I raised everything in place. I had to skinny my hands in there & remove it to free it up. My custom seat box probably made it tighter than it would have been.
Now here's an odd one - The original transfer box, that came with the 2.5 NA, has four tapped holes to mount the parking brake bracket. The transfer box that I just removed has six (two unused), so I was still able to use it. The transfer box that I just installed has only two!

Original & the brake bracket.

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The one I just removed.

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The one I just installed. There are no holes tapped in the mount location.

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Is there a different parking brake bracket?
 

Napalm00

Technical Excellence Contributor
There are two different types of parking brake bracket yes. Maybe easier just drill and tap your case?
 

Tbaumer

Technical Excellence Contributor
I think that is the new plan. Wish I would have noticed the missing holes when it was out, but there is enough room to drill & tap it.
Or upgrade to the XBrake - Anyone have one that can tell me how the cable mounts? Is the old bracket discarded or still used?
 

Napalm00

Technical Excellence Contributor
on my very old Xbrake the old bracket is not used. the cable attaches directly to the caliper/mount that bolts the front of the tcase output. ive said it before , the xbrake saved my life.
 
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