The Land Rover transfer case gets a must needed upgrade before mounting & back at it full speed after some delays. The common failure points in these Land Rover LT230 transfer boxes are: 1) The center differential spider gear pins & 2) the intermediate shaft's bore in the case. The former is a relatively easy fix via Ashcroft's upgraded cross pin (cross shaft, center pins, etc) that replaces the 2-piece pins that often fail during extended off road travel or long bouts of wheelspin. The latter is a much more in depth process requiring a complete tear down, then sending the case to a machinist where they'd cut a new bore & press in a special hardened support bushing. I was very relieved to find the intermediate shaft on my particular case was in great shape & won't likely need machining for a while! Every bit of information I could find on accessing the diffs internals required near complete disassembly AND pulling off that giant taper bearing... but that would require resetting gear lash & replacing a few big difficult bearings. In my experience you can "sneak" out bolts like this from under the bearing in a series of steps much more easily. Taking a multi-day project down to a mere hour!
~ PART#19 in a project dubbed "Nanuuq" to swap out my lifted Land Rover Discovery 2's blown 4.0L V8 & boring ZF auto for a Cummins 4BT 3.9L turbo (Holset Super HX30W) diesel 4-cylinder engine (Bosch P7100 pump) with an NV4500 5-speed manual transmission. The AWD 4x4 will remain with the LT230 transfer case divorced behind it all, & plenty of Dodge 6BT parts too. Another big phase of my custom DIY build to create a do-just-about-anything off-road / overland rig. Did I mention it's a camper too?
~ BUILD THREAD: (Entire build) https://www.overlandbound.com/forums/threads/10336/
~ BUILD THREAD: (4BT specific) https://www.4btswaps.com/threads/100657/
~ SONG: Slinger's Song - by Darren Korb
~ DISCLAIMER: Please do not do/repeat/imitate/recreate anything I do in my videos. JUST DON'T! It can be very harmful to bystanders, your person, your wallet, & your psyche. Don't risk the only "meat vehicle" you get!