This is a very popular gear set, especially for those with a TD5 90/110 or Tdi which revs excessively on the motorway. This gear set will enable you to raise your transfer case gearing by 15%, by replacing the gears in the exising 1.410 ratio transfer box with new 1.222 gears, as used in the Disco. This will not only reduce your revs but also reduce noise. This change will not effect Low Range and will leave your Speedo reading true.
This kit offers a simple and effective change to your vehicle and there is nothing to go wrong.
You may find it useful to use our ‘ratio calculator’
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).
Please select from the dropdown above whether you have the later, thinner type engagement teeth or the earlier, thicker type engagement teeth.
Please see the photo below to help you identify your engagement teeth, note the upper teeth are the later, thinner type and the lower teeth are the earlier, thicker type.
Sometimes a new input gear is required when fitting a gear set. If going to a 1.003, 1.4 or 1.6 ratio, a 26-tooth input gear will be needed. This could be FRC5428, FTC5089 or FTC4962.
Please see below to determine whether a new input gear will be required:
Suffix C to serial number XXD308626E uses a FTC5089. A new input gear will not be required.
If the old unit is a 28D and number is after 28D308626E then it has a 28-tooth input gear e.g. FTC5087. A new input gear will be required.
If the old unit is a 36G, 41G, 42G, 68G, 69G, 70G, 80G, 81G etc this will have a 38-tooth input gear. A new input gear will be required.
If you have a 43G/57G, you will have a FTC4962. A new input gear will not be required.
Suffix A and B will be thin, FRC5428
Suffix C to F will be 5089
Suffix G will be FTC4962
If you require a new input gear, this can be ordered along with the gear set. Please see here.
In order to calculate your shipping costs you will need to put the items in your shopping basket and confirm your delivery address. Once you have entered these details a shipping quote will be generated. Please do not proceed to the payment stage unless you are ready to order.
1) you should have these parts :
2) remove sump,
3) remove hi/lo housing
4) remove the 8 bolts holding the front housing on,
5) remove 30mm intermediate pin nut
6) remove pin
7) remove front housing,
8) remove detent screw
9) remove spring and ball,
10) remove diff assembly,
11) remove large nut,
12) press off top bearing,
13) refit low gear and the inner selector hub, note the outer groove goes to the low gear side,
14) before you fit the outer selector hub and new gear pls check the selector collar drops on the gear, sometimes the sharp edges will stp it dropping over the dog teeth like this :
15) if it doesn’t drop on just knock it on with a mallet and then it should fit OK,
16) press the gear, top hat and bearing back on,
17) refit nut,
18) when the nut is tight, check the gear spins freely,
19) peen the nut,
20) fit fork to diff
21) knock old bearings out and press into new gear,
22) Clean all faces,
23) refit diff,
24) apply sealant,
25) refit housing,
26) check it spins freely,
27) put sealant on pin head,
28) and hole in casing,
29) and other hole,
30) put gear in with bearings, use rope and rule,
31) lower gear in with the new collapsible spacer between the bearings,
32) push in pin,
33) tighten intermediate nut,
34) you will need to tighten the nut until the spacer collapses, you can feel this as the drag will increase which you will feel if you keep spinning it as you tighten the nut,
35) you should see about 1 thread,
36) apply some oil and check it spins OK,
37) peen the nut,
38) apply sealant,
39) refit sump,
40) apply sealant,
41) refit hi/lo housing,
42) refit ball, spring and plug,