I will be swapping my BWTC for a 1995 Disco locking LT-230 TC sometime in August in my RRC.
Since I only drive my RRC <2,000 miles a year, is it really necessary to cross-drill the output shaft on my TC main gear...?
This is the very short version. No.
If you are wheeling or pulling, or generally abusing the truck a lot, then the easiest way is to buy a later type input gear for around $80 (I think that is what I can do one for, but will need to check). It should be FTC5089/5087/4850 (I'd need to know the box serial number). You will also need to check that you have the longer splined output shaft from the gearbox (if auto, all manuals I think have the longer splined shaft) otherwise you'll wonder why the two won't quite close up (ask me how I know ....).
You can drill them, if you have a very hard drill bit, take it real slow, with plenty of lube ..... (wait for the smutty comments), but you'll still not get the longer splnes which are stronger.
Now wait for the "Q" verses "T" strength discussion .....
Graeme Ware -- San Carlos, CA
1990 Range Rover Classic - LT230 Transfer box, Warn winch, 2" lift, 235/85-16 Dunlop MUD Rovers, "Blue Submarine"
1996 Discovery 1 (R380 Manual Transmission, Ashcroft under-drive, RoverWare rear bumper, 33x12.5-15 BFG ATs) -- we call her "Katrina" -- Fordyce 7.5 mile survivor
1999 Discovery 2 (D1 CDL Linkage, 265/75-16 BFG A/T KO, RoverWare front and rear bumper)
1993 Jaguar XJS convertible; 1971 Triumph GT6; 1959 Morris Minor convertible
other assorted British pot metal ...