So you want to rebuild your own LT230 Transfer Box. Its not as difficult as you might think. Here you will find a complete rebuild kit along with optional upgrades for you to carry out your own rebuild. 

Please read through the complete description to help identify which components you require.

New Gearset

Selecting a new Gearset

1.6, 1.4, 1.3, 1.22, 1.1, 1.003 are all compatible with either 26 tooth input gears (FTC5089 & FTC4962) 1.21 requires the 36 tooth (FTC4850 SS IEH500140)

These have the thinner type engagement teeth on the high gear and so will fit the LT230’s with serial number XXD226368E and later.

If you want to fit this ratio to a unit with a serial number before XXD226368E, you will have the thicker engagement teeth so you will also need FTC1084 (low range gear) and FTC382 (high/low hub)

As a general rule all TD5 & TDCI Transfer boxes are Thinner engagement as are most 300 TDI boxes. 

1.22 Vs 1.21Q There is next to no difference in ratio value between these two gearset options. The difference is the 1.21 Q Gears have more teeth and are a more refined cut giving a quieter run. However these gears are not as strong as the 1.22 Gears. We recommend that if you have a high powered Land Rover to choose the 1.22 option.

Input Gear

26 tooth FTC5089   (130mm)

26 tooth FTC4962    (135mm)

Both of the above input gears are compatible with all gearsets with the exception of 1.21 and 0.9 ratios. The fundamental difference between these two gears is the over all length FTC5089 being 130mm and FTC4962 being 135mm (see picture)

These can also be identified by the thickness of the PTO plate.

16mm requires FTC4962

11mm requires FTC5089

38 Tooth FTC4850 Supersedes to IEH500140 This input gear is only compatible with the 1.21Q Gearset.

Centre Diff

The Heavy Duty cross pin is compatible with all LT230 centre diff excluding the very last TDCI Years.

The ATB has two options 

Type A – RRC, Disco 1, all Defender pre TD5, Serial numbers starting 20D, 22D, 25D, 26D, 28D, 29D, 36D, 37D

Type B – Disco 2, TD5 and TDCi Defenders, Serial numbers starting 41D, 42D, 43D, 57D, 60D, 61D, 62D, 68D, 69D, 70D, 80D, 81D

These are the basic component that come with each base rebuild kit.