land rover transfer gears- what material?

[Tinbasherdan]

anyone any ideas on the above? to save a bit of money for the time being on my conversion im going to be welding an extension to the input shaft, so could do with knowing what sort of rod to use really! it has been done before with great success but the guy has no information on what his welder used. there is a 1 piece billet shaft available but its the wrong side of 300 quid and if i can save that at the time being it would be a bonus. as im having to replace the input whether it breaks or i get a billet im not losing anything with trying a weld.

 

[Kent]

anyone any ideas on the above? to save a bit of money for the time being on my conversion im going to be welding an extension to the input shaft, so could do with knowing what sort of rod to use really! it has been done before with great success but the guy has no information on what his welder used. there is a 1 piece billet shaft available but its the wrong side of 300 quid and if i can save that at the time being it would be a bonus. as im having to replace the input whether it breaks or i get a billet im not losing anything with trying a weld.

En19?

 

[jeremy]

Not alot of help i'm afraid. But most of the experience i've had with Land Rovers over the years,
I've found them to be made of cheese and iron oxide.

 

[Tinbasherdan]

Not alot of help i'm afraid. But most of the experience i've had with Land Rovers over the years,
I've found them to be made of cheese and iron oxide.

The lt230 is actually renowned as a very strong box

 

[Tinbasherdan]

En19?

Could be, I’ve seen 4140 quotes in some places but that could be an uprated one

 

[gaz1]

wouldnt you be better extending the transfer bar than actually trying to weld onto the tranfer shaft

 

[Tinbasherdan]

wouldnt you be better extending the transfer bar than actually trying to weld onto the tranfer shaft

Internal splines disintegrate on the input with the torque that the Cummins puts through it, people have tried making a spud shaft and theyre useless. i think its 50mm that the input gear needs to protrude from the transfer casing, so you use the original yoke off the zf box and turn it down

 

[gaz1]

Internal splines disintegrate on the input with the torque that the Cummins puts through it

so if you do that spline wouldnt you also have to do the big spline as well as you may strip the other spline if the other is over hardened

these are from a stripped big spline inside the rear transfer box

 

[Tinbasherdan]

so if you do that spline wouldnt you also have to do the big spline as well as you may strip the other spline if the other is over hardened

the zf spline is a lot finer than the lr spline and transmits the torque much better, it was after all designed for that application. youve got to remember im going from an engine that supplies 190lbft to one the supplies 440 in std trim, it just eats the smaller dia and splined lr input. im asking the question so i dont over harden it

 

[Tinbasherdan]

so if you do that spline wouldnt you also have to do the big spline as well as you may strip the other spline if the other is over hardened

these are from a stripped big spline inside the rear transfer box

View attachment 167397

are they not helical gear teeth? the input splines on an lt230 are nowhere near that big

 

[pressbrake1]

Iveput more cummins in landrovers than Ive had hot meals. did my first in 1999 now everyones done it
get the input gear on lt230 wire eroded out to bigger spline.

 

[gaz1]

we could be on about different things here

im on about this

https://www.ebay.co.uk/itm/LAND-ROV...h=item33f889c864:g:RnwAAOSwDDRb2v9-:rk:7:pf:0

those bits came from inside of there

 

[Tinbasherdan]

we could be on about different things here

im on about this

https://www.ebay.co.uk/itm/LAND-ROV...h=item33f889c864:g:RnwAAOSwDDRb2v9-:rk:7:pf:0

those bits came from inside of there

thats a diff, im talking about the actual transfer box which splits the drive between the two axles

 

[Tinbasherdan]

Iveput more cummins in landrovers than Ive had hot meals. did my first in 1999 now everyones done it
get the input gear on lt230 wire eroded out to bigger spline.

i know who you are now you made a new tail housing i believe, im using reeces copy of simons conversion kit he fitted in his 110 in oz, so i cant just edm the splines as the input is still about 50mm too short

 

[Tinbasherdan]

incidentally pressbrake, ive made a few quid fitting your crossmembers in the past

 

[pressbrake1]

i know who you are now you made a new tail housing i believe, im using reeces copy of simons conversion kit he fitted in his 110 in oz, so i cant just edm the splines as the input is still about 50mm too short

yes Im prone to getting the horn and getting a bit fancy.
Ive seen the spuds just welded with a mig and held up fine.
If I ever did another id get hold of a np 205 transfer box as its strong with 1:1 gearing actually I have one stashed up just incase

 

[pressbrake1]

incidentally pressbrake, ive made a few quid fitting your crossmembers in the past

I knocked them on the head over two years ago . I still get asked to fit but im not sure I could make myself, I fitted over a thousand so ive paid my dues!

 

[Tinbasherdan]

yes Im prone to getting the horn and getting a bit fancy.
Ive seen the spuds just welded with a mig and held up fine.
If I ever did another id get hold of a np 205 transfer box as its strong with 1:1 gearing actually I have one stashed up just incase

not got the money for a 205, so lt230 it is. simons welded shaft has done 10s of thousands of miles in oz and is fine, so itll be the way im going for the time being. do you have any drawings for the tail casing on the zf? or was it the spicer you used?

I knocked them on the head over two years ago . I still get asked to fit but im not sure I could make myself, I fitted over a thousand so ive paid my dues!

about the time i stopped as everyone wanted a rolls royce job for metro money

 

[8ob]

i know who you are now you made a new tail housing i believe, im using reeces copy of simons conversion kit he fitted in his 110 in oz, so i cant just edm the splines as the input is still about 50mm too short

Dan the firm that cut the gears in those transfer boxes for Landrover were in Wokingham, if they are still going it may be worth giving them a call as they have/own the oddball tooling that cut them . The last time I used them they cut me a 50% overdrive set for about £250 IIRC, they could possibly make you a set with whatever spline or spigot size you want.

Bob

 

[Tinbasherdan]

Dan the firm that cut the gears in those transfer boxes for Landrover were in Wokingham, if they are still going it may be worth giving them a call as they have/own the oddball tooling that cut them . The last time I used them they cut me a 50% overdrive set for about £250 IIRC, they could possibly make you a set with whatever spline or spigot size you want.

Bob

interesting, ill have a look at that