The noise from the drivetrain increased during the trip. Secondly, the transfer case was losing a lot of oil, a common Land Rover problem. It was clear that we had to get this sorted out before any more trips. So we looked through the literature, looked at Ashcroft's website and that's how the project took shape. It was important from the start that there was no time pressure. That's why Luis was placed on stable stands so that he could stand without wheels and I could remove the parts and, if necessary, repair or replace other areas.
1) new transfer case
2) Differentials?
3) Drive shafts?
4) Ball joints at the front?
5) new bearings?
To get straight to the point, almost all questions were answered with yes. According to the motto, once you're in, you'll do everything.
Shop at Ashcroft - https://ashcroft-transmissions.co.uk/
After many discussions and research, I decided on the following solution:
1) new transfer case, no overhaul but the new design LT230 new - https://ashcroft-transmissions.co.uk/product/lt230-new/
2) new front differential with the extension to a limited-slip differential https://ashcroft-transmissions.co.uk/product/rover-type-diffs/ and https://ashcroft-transmissions.co.uk/product/ashcroft-atb/
3) new rear differential with the extension to a limited-slip differential
https://ashcroft-transmissions.co.uk/product/p38-rr-110-rear-diff/
and
https://ashcroft-transmissions.co.uk/product/ashcroft-p38-wolfe-atb/
and here you can read everything again
https://ashcroft-transmissions.co.uk/product-category/limited-slip-differentials/
and if you want to understand the function of a differential here again
https://ashcroft-transmissions.co.uk/product-category/rebuilt-differentials/
Removal and installation of transfer case LT 230
I was really scared about whether I could do it alone. Firstly because everything is very heavy and secondly because it was my first time because watching and helping is a different thing. But it worked, even better than I thought. With the jack you can position the gearbox very well and then you just have to push it onto the shaft, done! Of course the exhaust and the cardan shafts had to go. The cardan shaft bearings were repaired in Chile, so they were able to stay.
further optimizations - if so, then so
1) the wheel bearing mount had suffered from the many wheel bearing changes, they will be replaced
2) the drive shafts are worn out, they will also be replaced
3) the ball joint on the passenger side has not yet been replaced, now it is time
and then everything is new.
No, we are also replacing the tie rods, the track has not been adjustable for a few kilometers, but more about that later