Outer Limits 4x4 Board

How hard is it to remove the tranfer case from a disco 1 manual. I need to replace seal.While its off would like to change low range gearing to make it better when i put my 33" simex on. Who does gears for that.

it is not to hard to split the transfer off in the car you will have to drop the xmember to let the box drop far enough for the handbrake drum to clear though when you put it back in watch the seal between the two boxes as it is damaged easily

Transfer case removal is easy. Undo your exhaust, drive shafts and all transfer linkages and handbrake. Then it's simply a matter of undoing about 8 bolts that hold it to the gearbox. There is also the mount on one side of the TC to do. The other mount is attached to the gearbox.
I've done a few and never had to drop the crossmember. You only need to do that when dropping the gearbox.
I actually pulled out a gearbox and TC on saturday, all up about 5 hrs work. Experience tells me it'll take 5 times that to put it all back in.

One bit of advice, pull out you centre consol and do all the stuff inside the vehicle first. Easier to keep things clean that way.

Like all of above tho remove the hand break drum and backing plate this will make it lighter and easyer to remove ...

When re fitting get some bolts a bit longer than the TC bolts u will need the same thread as the TC bolts cut the heads off these and screw a few into the back of the gearbox to use as guides so the seal dosent get damaged wile fitting the TC

Thanks fellas for easyer tips. Any ideas on gearing to lower it to suit 33".

advdisco1 wrote:Thanks fellas for easyer tips. Any ideas on gearing to lower it to suit 33".

33's should be ok with std gearing with a V8 tho TDI should be ok but some guys like to change it back to sorta std gearing by fitting 4.11 ring and pinion gears theres a few places you can get them like ashcroft or rover trax in the US