Outer Limits 4x4 Board

Hi all

I have researched outers regarding the installation of the maxidrive 30% reduction transfer gears into a LT230.

I have spoken with Warren from MR Automotive at Redcliffe (who now distribute MD gear) and he says the kit is available in DIY form. I just need to remove my intermediate gear and send to him for machining.

Anyone done this in the comfort of their own garage? I am thinking about doing it myself and I am just wondering if there are any tricks? I understand there is some grinding involved to fit the new low range gear.

At $1650, it is well on the money.

Cheers
Andrew

Think I paid $1800 delivered to Mal in '04 for a second hand 1.2:1 LT230, with 30% reduction that was sitting on the shelf. At the time was way way cheaper and easier that the DIY route.

Somewhere sometime ago I managed to get the DIY instructions for the kit. From memory, they read as it being a dead-set easy task. Grinding of the case was only required with the installation of the large gear in the 40% kit. 30% gears fitted straight in. (Apparently)

I thought grinding was only for the 49% kit also.

I put the 30% reduction gears in the LT230 in my rangie (the other ratio was not available at the time).

The LT230 has to be one with taper roller bearings for the intermediate gears (can't be done for the earlier LT230 with needle rollers).

For the 30% reduction gears, I had to grind material from bosses inside the case and also the rod for the selector fork. The gear was larger in diameter than the hole in the rear of the case where the rear output housing bolts up - the gear has to be fitted through the rectangular opening underneath.

It is a job that you can do yourself with a smallish angle grinder.

86MUD wrote:Hi all

I have researched outers regarding the installation of the maxidrive 30% reduction transfer gears into a LT230.

I have spoken with Warren from MR Automotive at Redcliffe (who now distribute MD gear) and he says the kit is available in DIY form. I just need to remove my intermediate gear and send to him for machining.

Anyone done this in the comfort of their own garage? I am thinking about doing it myself and I am just wondering if there are any tricks? I understand there is some grinding involved to fit the new low range gear.

At $1650, it is well on the money.

Cheers
Andrew

andrew they dont distribute MD gear they now make it for themselves bud, not sure if its the 30% as well , but the 49% i know is a bit of mucking around to fit.

Sorry Def90 you are right...

Warren at MR Automotive said the DIY kit was fairly easy to do for 30% reduction gear.

Are there any tricks to removing the transfer box? Is it just a case of removing tailshaft, handbrake drum, disconnecting the gearshift lever mechanism and then removing the box?

Cheers

Andrew

Pretty much....just keep undoing bolts until it all falls out

86MUD wrote:Sorry Def90 you are right...

Warren at MR Automotive said the DIY kit was fairly easy to do for 30% reduction gear.

Are there any tricks to removing the transfer box? Is it just a case of removing tailshaft, handbrake drum, disconnecting the gearshift lever mechanism and then removing the box?

Cheers

Andrew

You don't hav to remove the handbrake drum, but it will make it lighter and it has to come off eventually.

If you remove the input gear, you will find it a bit easier.

Definitely re-bolt the t/case to the gearbox with the input gear removed as it is much easier. Also make up some studs to the t/case back on.

Depending what high range ratio you have, you may have to rotate the intermediate gear so the input gear will pass the low range gear.

Try a matress or a old spare tire under it when she is ready to drop as they are bloody heavy. Especially when you are on ya back covered in rover oil under a car.
There are 2 hard to get to bolts in the centre of the case on the auto / gearbox side that you may miss.

i heard that the reduction gears are straight cut
and could be a bit noisy. dont know weather thats
an idea thou.

advdisco1 wrote:i heard that the reduction gears are straight cut
and could be a bit noisy. dont know weather thats
an idea thou.

yes they are straight cut, noisy yes compared to the OEM gears, but in reality they are only when ingaged doing low range work. doesnt both me at all, i have the nosier 49%

its a rover after all , not a bently

Serg

Heh!, yeah - she whines like nuffin else when doing 40kph in 5th gear at 2500rpm in low range - 200tdi. (Should really not do this...)