Land Rover Defender 90 110 Workshop Book 3 Rover

LT230R TRANSFER GEARBOX 137 
*.I.. -- ‘h 76. Using a suitable press behind  the low  range 
(largest)  gear carefully  remove both 
high/low hub 
and  low range  gear together.  Alternatively,  the 
rear  carrier  bearing,  high output  gear and bush, 
high/low hub and sleeve  and low output  gear can 
be  pressed  off 
in one operation  by supporting  the 
differential  side of 
the low gear. 
77. Using soft jaws secure  the differential  unit in the 
vice  by gripping  the inner  hub splines. 
78....

1371 LT230R TRANSFER GEARBOX 
ST1170M 
96. Remove the eight securing  bolts and lift off the 
97.. Remove  the bevel gears and  thrust washers,  and 
98. Select  correct  thrust washers  required  for  final 
front 
differential  case. 
side  gear 
asscmblies. 
reassem bly. 
Reassembling 
99. Fit the selected  thrust  washer  and  bevel gear to 
the  rear  (lower)  differential case. 
100.  Assemble  the side  gears  and  dished washers 
on 
their respective  shafts and fit to the rear case. 
101. Fit...

LT230R TRANSFER GEARBOX 
,,?:I:. ,. , :. . ,%a .. . ., .., 
Front output  shaft housing - Overhaul 
(Instructions 
125 to 175) magnet. 
Dismantling 
124. Secure  the housing  in the  vice,  using  soft jaws. 
125.  Remove  the seven  screws securing  the differential 
lock  selector side covcr and  release 
thc side cover 
and  gasket. 
126. Remove  the three  screws  securing  the differential  128. 
Remove 
the detent  plug  from  the top of the 
housing  and 
lift out the  spring  and  ball  using a...

137 I LT230R TRANSFER GEARBOX 
138. Using  circlip  pliers 186257 remove  the circlip. 
139. 
Remove  the housing  from the vice and  drift  out the 
140.  Press  out 
the differential  front  bearing  cup and 
141.  Clean  all parts ensuring that  any traces 
of Loctitc 
142.  Renew  oil seals  and examine  all parts 
for wear or 
bearing  from inside. 
remove 
the shim  behind it. 
are removed from  faces and threads. 
damage,  renew as necessary. 
Reassembling 
143.  Press  the  front  bearing into...

LT230R TRANSFER GEARBOX 1371 
167.  Slide the  dog sleeve onto the  rear of the output 
shaft  ensuring that  the selector groove  in 
thc dog 
sleeve  is to  the  front. 
168.  Compress  the differential  lock selector  shaft 
spring, and 
fit it between the sclcctor fork lugs. 
169.  Locate  the  selector  fork  inside the side  cover 
aperture 
in the  housing  engaging  the groove in the 
dog  sleeve  on the  output  shaft. 
170. 
Fit the  differential  lock selector  shaft into the 
housing  from...

LT230R TRANSFER GEARBOX 
208 192,199  194,198 191.197 
Highllow selector housing - Overhaul 
(Instructions 
189 to 205) 
Dismantling 
189.  Remove the selector  fork grub screw completely. 
190. Rcmove  the cross  shaft retaining circlip. 
191.  Withdraw 
the cross  shaft from the  selector 
housing 
with the  operating  arm attached. 
192.  Lift  out 
thc sclcctor fork from  the housing. 
193.  Remove the  two 
‘0’ rings from the cross  shaft. 
194.  Remove the operating arm  from the cross  shaft by...

LT230R TRANSFER GEARBOX (371 
c,+::,i3 *.rr:-. 218. Repeat  above  procedure and fit the rear taper 
pzq roller  bearing. 
219.  Lubricate  both bearings 
with oil. 
220. 
Fit input  gear assembly into  the transfer  box from 
the rear  (gear  end first). 
Obtaining  bearing pre-load - with intermediate gear 
cluster  removed 
221. Secure  the mainshaft  bearing housing  in the  vice. 
222.  Press  out  the rear input gear bearing  cup  and 
223.  Clean  the main  bearing  housing  and measure 
224. 
Fit...

El LT230R TRANSFER GEARBOX 
249. Apply  Loctite  290 to the  lock  plate  bolt threads. 
Locate  lock plate 
into position  and fit securing 
bolt  (with  spring  washer). 
250.
- Using  a screwdriver  via the  bottom  of the transfer 
case 
lift up  the  gear  assembly  and measure  the 
end
-float  with feeler  gauges.  This  should  be 
between 
0,08 and 0,35 mm (0.003  and 0.014  in). 
251.  Grease  and 
fit the bottom cwer gasket. 
252.  Apply  Loctite  290 
to the ten bottom  cover  fixing 
253....

LT230R TRANSFER GEARBOX 
.- .. c. ::.. I I .. ... I,: .~ .. ... 
270. Rcmove  the two  countersunk  screws from the 
271. Remove  the housing  end cover. 
272. Remove  the two ‘0’ rings from  the end  cover. 
273.  Remove 
the cross  shaft from the housing. 
274.  Compress 
the detent  spring and  remove the gcar 
change 
arm from inside  the housing. 
housing 
end cover. 
Reassem biy 
279. Fit the two ‘0’ rings  to the  housing  end cover. 
280. 
Fit the  two ‘0’ rings  to the gear change  crank arm....

137 I LT230R TRANSFER GEARBOX 
299. Before  refitting  the high/low connecting  rod and 
gear  change  operating  arms remove  the respective 
clevis  pins and Nylon  bushes.  Clean and examine 
for wear or damage,  renew as necessary. 
300.  Grease  and 
fit the Nylon  bushes  to the high/low 
selector  and gear  change  opcrating arms. 
301.  Assemble  both operating  arms to the  connecting 
rod  with  clcvis  pin, plain  washer  and split  pin. 
302.  Slacken  the gear  change  operating  arm clamp...