White Swan Disco Overland #landroveryo build

I just picked up a project 99 land rover Discovery II. It's got the Bosch 4.0l that runs fine, but the auto trans won't pickup any gears. The owner kept having to Jumpstart it and fiddled with the battery cable terminals, I tightned the cable in the clamp and haven't had another issue.

 

Mine

 

Mine

 

In for the White Swan

 

Mine

 

Diesel swap?

 

Sub

 

After checking out the trans fluid (good and full), watching lots of YouTube, I now believe that the problem isn't the ZF transmission but the LT230 transfer case. Either the center differential spider gears/pins or the input gear splines.

https://landroverforums.com/forum/discovery-ii-18/transfer-case-removal-pictures-75584/

Interview with Ashcroft:
https://youtu.be/vFHCYuPTbfg

Input gear:
https://youtu.be/7vFPc5ZSRKg

https://youtu.be/gndYfwGqg0c

Center differential:
https://youtu.be/vi5kHtvY-u8

https://youtu.be/xsjs49aj6J0

 

Both the CDL and input shaft splines seem to be fine. Now either gear teeth are missing or it's stuck in neutral, gonna have to drop the exhaust to check any further.

 

Window regulator replaced, $35 from Amazon.

https://youtu.be/iKuPFjp3shU

 

@Taco_life this is your fault , you should subscribe to this thread.

 

I'm to the point I think the problem is the T-case is stuck in neutral. I've been reading and others have had stuck or broken linkages. I'm going to get a new shift handle, with CDL, so I can install it while I have the center console out to inspect.

 

The cable and linkage move as they're supposed to. Now it's time to finish moving the exhaust to open the bottom of the transfer case.

 

Cool project.
I award you 10 extra credit points for problem solving skills and patience.

 

is this Disco Worthy ?

https://youtu.be/ccvUstooIfw

 

I do have a pretty solid temper and focus. It definitely pays off to troubleshoot and take my time to work through issues rather than just shelling out money.

https://youtu.be/XCc4rDU-24I

 

And here's your problem. It looks like the transfer case oil "leaked" out (doesn't look like it was leaking), the bearings and shift fork wore out, and then the shift fork(brass) detonated leaving the transfer case in neutral.
On a positive note, the input shaft has the oil hole that they added later on to keep the splines from wearing out.

 

$144 junkyard T-case w/85000 miles, 90 day warranty

 

To the garage with the PB blaster... I may need to buy more.

 

Got the y-pipe out with relative ease, impact gun made quick work of the stud nuts none broke! Also pulled off the driveshafts.