No gears, rolls in park!

jmkinggg

Member
First off, the ODO has to pass a million miles to "roll over" so you probably have only the 82K on it.
Second, The transfer case is probably the original Borg Warner so there's no diff lock.
I have had this happen in one of my previous RRC loobs. On Christmas Day pulling out of the Chinese restaurant (it was packed with people by the way!). It was accompanied by a pretty good bang. I never actually diagnosed the problem but I'm pretty sure I broke the drive chain in the transfer case. That truck went straight off to be parted out by my buddy Rob.
So I would plan to get the transfer case out of there. This is an excellent opportunity to switch to an LT230. You will need the shifter off a D1. If you can find a transfer case locally then this shouldn't cost you anything more than a few hundy and some elbow grease. Repairing the Borg Warner will be, to say the least, expensive. Possibly even impossible as the parts are really difficult to come by. The viscous coupling I mean. There's no point in rebuilding without putting in a new VC and they just aren't out there.
So, happy wrenching!
So I?m thinking of doing the LT230 swap. The problem area seems to be at the input gears where the transfer case and transmission connect. All the noise is coming from that spot. What do you think that could be? Hopefully it?s not the main shaft from the transmission. What would just be spinning in place in the transfer case? Gears worn down? Chain? Chain would be a different sound I think. When I was driving and this happened it was all of the sudden no gradual problems.

What year of the LT230 would I need and do you have any tricks or tips in getting the tcase out?

Thanks so much.
Jon King
 

jmkinggg

Member
Regarding swapping to an LT230 on my 93 Range Rover Classic 4.2. Does anyone know if the later LT230 from the disco 2 without CDL would swap onto my Range Rover. I?ve heard from people that the LT230 from the 94 to 98 with CDL will swap directly. I?m not a hardcore 4 wheeler so I?m not super concerned with having CDL.

I?ve found a later one with the number 62D972760G the seller says it has 155k on it and I want I want to get my truck back on the road. I?m thinking of purchasing the rebuild kit for it as well. Thoughts? Suggestions? Thanks guys!
 

Red90

Well-known member
You need a CDL is you are going off road at all. You won't get 10 feet without it. The Disco 2 uses traction control to overcome the missing locker.
 

Uncle Douglas

Well-known member
Regarding swapping to an LT230 on my 93 Range Rover Classic 4.2. Does anyone know if the later LT230 from the disco 2 without CDL would swap onto my Range Rover. I?ve heard from people that the LT230 from the 94 to 98 with CDL will swap directly. I?m not a hardcore 4 wheeler so I?m not super concerned with having CDL.

I?ve found a later one with the number 62D972760G the seller says it has 155k on it and I want I want to get my truck back on the road. I?m thinking of purchasing the rebuild kit for it as well. Thoughts? Suggestions? Thanks guys!
Your classic needs a speedometer drive. You need a tcase from a truck prior to the d2. In order to put a lt230 in your truck you will need to change the transmission tail shaft. The splines on it arent cut deep/long enough for an lt230 input gear. Its an easy 5 min job to swap.
 

Jeff B

Well-known member
Hopefully it?s not the main shaft from the transmission. What would just be spinning in place in the transfer case? Gears worn down?

It could be the splines on your transmission tailshaft are so far gone that's what you're hearing.


But like Uncle Doug said, you're going to change that out (2 minutes=1 bolt) when you swap the transfer cases.




.
 

Napalm00

Well-known member
If you hear any noise from the transmission to transfer case area your transmission output splines must of stripped. It's a surprisingly common failure.

it would also explain why you are rolling in park and have no gears since the transmission has no real connection to the wheels.
 

jmkinggg

Member
It could be the splines on your transmission tailshaft are so far gone that's what you're hearing.


But like Uncle Doug said, you're going to change that out (2 minutes=1 bolt) when you swap the transfer cases.




.
Where would I find the replacement correct tailshaft for the swap if it is stripped?
 

Uncle Douglas

Well-known member
If you hear any noise from the transmission to transfer case area your transmission output splines must of stripped. It's a surprisingly common failure.

it would also explain why you are rolling in park and have no gears since the transmission has no real connection to the wheels.
He has a Borg Warner now, not an lt230.
The output spline issue is only with manuals and lt230's
 

jmkinggg

Member
This isnt your issue
Thanks for clarifying Uncle Doug.

I'm swapping from the borgwarner to an LT230 from the disco 1.

Things I need:

LT230 with mounting brackets
Front drive shaft
the disco 1 lever and linkage
longer splined coupler so that my ZF transmission will connect to the LT230?

Trying to get some clear answers on what I need before I start ordering random things.

Thanks so much.
 

Viton

Well-known member
When I did my repower to a 300Tdi in '01, the Zf4hp22 that came to me from the UK, with the correct shift body for the Tdi, the tranny did not come with the output shaft to join the LT230Q. Yes, there are 2 different length shafts. When I finally got the correct length, I used the standard "Blue" Loc-Tite on the long bolt that secures it to the tranny. This misake came back to haunt me 10 years later as the "Blue" is not make to play well with ATF. The bolt backed off slowly over time, then BAM !!, one day it would only shift from 1st to 2nd., no 3rd or 4th. The shift body, in the rear section of the trany was no longer secured in place. The round rubber seals back there had fallen apart and found their way into the pan. Long and short of the story use Loc-Tite 266 on this bolt. The sequence is on the bolt, flat washer 1st, then the sealing "O" ring on the bolt, then apply the 266 to the threads, insert, torque, & indicate mark the head of the bolt & trany splined shaft for future reference that it doesn't back out and cause the problems that I had.
 

Uncle Douglas

Well-known member
Thanks for clarifying Uncle Doug.

I'm swapping from the borgwarner to an LT230 from the disco 1.

Things I need:

LT230 with mounting brackets
Front drive shaft
the disco 1 lever and linkage
longer splined coupler so that my ZF transmission will connect to the LT230?

Trying to get some clear answers on what I need before I start ordering random things.

Thanks so much.
Suggest you call Will Tillery and tell him what you are trying to do. He likely has all of this used.
 

Uncle Douglas

Well-known member
No issues. It bolts right up to the zf and there are no other changes. same drive shafts etc. I know cz I did it. Only thing is the transfer case shifter from the RRC doesn't have to diff lock selection so you need a D1 transfer case shifter.
Depends on the lt230 Bill. If its from a 94 up truck you need to swap the output splined spud shaft on the trans. The splines on the Borg warner spud shaft arent cut long enough to work with the later tyle t case input gear. Takes maybe 2mins to swap, shaft is held on by a bolt.
 

jymmiejamz

Founding Member
Callsign: KN4JHI
It is always a good idea to replace the shaft as they almost always have a groove worn into them which allows fluid to leak out of the trans and/or the transfer case.
 

rover4x4

Well-known member
You'll need the LT230 parking brake cable, you'll need to trim the console as well.. this is a good time to replace the rubber engine and transmission mounts, at least I did...

Worthwhile upgrade.
 
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