Land Rover Defender 90 110 Workshop Book 3 Rover

LT230T TRANSFER BOX 
-_ .. . . _. . (.,. .. , , .: .... .. .... :  ... .. 11. Remove the eight  retaining bolts and lift off the 
12. Release the retaining  ring and remove  front  upper 
13. Rcmove the pinion  gears and  dished washers along 
14. Remove  the rear  lower  bevel gear and thrust 
front 
part 
of the differential unit. 
bevcl gear  and thrust  washer. 
with  the cross  shafts. 
asher from the rear  part of the differential unit. 
114 
ST 1 
15.  Remove thc rear differential unit from thc...

137 I LT230T TRANSFER BOX 
27. Invert the differential  unit  and repeat operation 26 
for the  rear  bevel  gear end-float. 
28. Invert  the  differential  unit and secure  in vice  and 
remove  the  four  bolts  and 
lift off the  front 
differential unit. 
29. Remove  the rctaining  ring, bevel  gear  and  the 
washer  and both pinion assemblies. 
30. Select the  correct  thrust washers  required  for  final 
assembly. 
Reassembling 
31. Fit the  selected  thrust washer and bevel gear into 
the  rear...

LT230T TRANSFER BOX 
.-- ,,,:~,:~~. . .... 42. Locate the rear  differential  bearing on to the  hub 48. Fit the new  selector  fork with  its boss  towards the 
three detent  grooves. Align the tapped  hole 
in the 
fork  boss  with  the indent 
in the shaft nearest to  the 
detent  grooves. 
49. Apply  Loctite 290 to the set screw  threads  and fit 
the set screw  and tighten  to the specified  torque. 
and 
press 
it into position  using the smaller  end  of 
tool 
18G1424. 
43. Fit the  stake nut and...

37 
2. Fit output housing  and ensure  clearance of 
1.00 mm (0.039  in) between  housing face and 
gasket. 
3.  Fit  the  six output  housing  bolts with Loctite  290 on 
the threads, with washcrs  and tighten  evenly  to the 
correct  torque,  which will pull  the rcar  bcaring  into 
position. 
LT230T TRANSFER BOX 
- ST1594M 
Centre  differential  unit refit 
1. Fit  the  sclcctor forkhhaft assembly  to the high/low 
selector  slecvc on the  differential  assembly,  with 
detent  groove  to the  rear...

LT230T TRANSFER BOX 137 I 
6. Withdraw the selector  shaft from the  rear  of the 
7. Remove  the selector  fork and spring  through  the 
side  cover  aperture. 
8 Remove  lock-up sleeve  from the rear of the output 
housing. 
4.: c\j dL output  housing. 
15. Invert housing  and drift  out bearing  from  inside  the 
case  as shown. 
9. Using  flange wrench 18G1205 and  socket  wrench, 
remove  the 
flange nut, steel and felt washers. 
NOTE: 
Ensure  that flange  bolts are fully  engaged  in 
the...

LT230T TRANSFER BOX 
Keassem bling 
20. Press the bearing  into the housing;  do not  use 
excessive  force. 
To facilitate fitting the  bearing, 
hcat the front  output  housing.  (This  is not  to 
exceed 
1 OOOC). 
21. Using  circlip  pliers 186257, fit the bearing 
retaining  clips. 
22. 
Fit a  new oil  seal (open  side inwards)  using replacer 
tool 
18G1422, until  the seal  just makes  contact with 
the  circlip. 
23.  Carefully  charge the lips  of the  seal  with  clean 
grease. 
24. Slide...

LT230T TRANSFER BOX 51 
41. Repeat  the above operation  for the  rear  output 
flange. 
42.  Compress  the selector  shaft spring  and 
fit to the 
selector fork. 
:i, ;:. 43.  Locate  selector  fork  through  front  output housing 
side  cover  aperture,  ensuring that 
the fork engages 
in the groove of the lock-up sleevc. 
44. Fit selector  shaft through  the  aperture in the front 
of  the  output  housing  and pass 
it through the 
sclector  fork  lugs and spring  into  the  rear  part c.f 
the...

37 I LT230T TRANSFER BOX 
7. Fit the differential  lock lever  over the pivot  shaft so 
that the lever  will face  forward with the bcnd 
upwards.  This lever  is then in the correct  operating 
position. 
S. Retain the lever  with a plain  washer  and new  nyloc 
nut. 
ST1618M 
High/low cross-shaft  housing  overhaul 
1. Remove the selector  finger grub screw  and 
withdraw  the cross
-shaft  from  the cross-shaft 
housing  and remove the 
selcctor finger, 
2. Remove  the ‘0’ ring from  the...

El LT230T TRANSFER BOX 
Checking input gear bearing  pre-load 
12. Secure bearing  support  plate in the vice.  Drift  out 
input  gear bcaring  track, and remove  shim. 
13. Clean hearing  support  plate and  shim.  Measure 
original  shim and note  its thickness. 
14. 
Fit the  original  shim to the  support plate. 
15.  Locate  the bearing  track 
in the support  platc  and 
press  fully home. 
16.  Apply grease  to the  gasket  and 
fit on to the transfer 
box  casing. 
17. 
Fit the  bearing  support...