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 vicc and 
clean  all components; 
examine Tor wcar or clamage 
and  renew if necessary. 
16. Clean  all components; examine  for wear  or damage 
and  renew 
if necessary. 
17. Using  soft  jaws  secure  the rear differential unit in 
the vice  by gripping  the hub splincs. 
IS. Ensure that all differential  components  arc  dry to 
assist 
in checking  end-float. 
19. Using a micrometer, measure one  of the bevel gear 
thrust  washers  and note  the thickness. 
20.  Fit the  thrust  washer and bevel  gear 
to the  rear 
lower differential  unit. 
21.  Assemble  both  pinion 
asscmblies and dished 
washers  on 
to their respective shafts  and fit to the 
rear  differential  unit. 
22. Measure the front upper  bevel gear thrust  washer 
and note  the thickness. 
23. Fit the thrust  washer  and bevel  gear to the front 
unit. 
24.  Refit  the retaining  ring and front  differential  unit, 
aligning  the two  engraved  arrows  marked on  both 
halves  of the unit. 
25. 
Fit four bolts  equi-spaced  and torque  to the  correct 
figure. 
25- 
26. Mcasure the  front  bevel  gear end-float  with fcclcr 
gaugcs through  the slots  provided in the front 
differential 
unit. The end-float  must be 0,025 to 
0,075 mm (0.001 to 0.003 in) maximum.  When 
measuring  use  two sets 
of feelcr gauges,  one  on 
each  side of the  front  differential  unit.  This 
will 
give a true reading  of the  end-float. 
97  
						

							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  lower  differential  unit. 
32. Assemble  both pinion  assemblies  and dished 
washers 
on to their  respective shafts  and fit the  rear 
differential  unit.  Secure 
the assemblies with the 
retaining  ring. 
33. Lubricate  all the  components. 
34. Fit the  selected  thrust washer  and  bevel gear into 
the  front  upper  differential  unit. 
S7 1 602 
ST 
35. Align both  units as previously  described and secure 
with  the eight 
bolts to the  specified  torque. 
36. Finally check that the differential  gears rotate 
freely.  Locate  the  front  differential  bearing onto 
the front,  upper  differential  shaft and press  into 
position 
using larger  end of tool 1861424 as shown. 
37. Invert the differential  unit and secure in the vice. 
NOTE: During  the following  sequences all parts 
should be lubricated  as they  are fitted. 
98 
38. Fit the  low  range  gear, with its dog  teeth  upper- 
most  to the  differential assembly. 
39. Prcss the highllow hub on to the differential 
spli 
nes. 
40. Slide  the high/low selector  sleeve on to the high/ 
low hub ensuring  that the alignment  marks  are 
opposite each  other. 
41. Fit the bush  into the high  range  gear so that the 
flange  is fitted 
on the  opposite  side of the gear to 
thc dog teeth.  Slide the bushed  gear on to the 
differential  assembly with the dog teeth down. 
41 
39 
ST1599M  
						

							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  tighten  to the  specified  torque 
using 
tool 18G1423. 
44. Check  the cnd float of the high  and low rangc gears 
0,05 to 0,15 nim (0.002 to 0.005 in). 
NOTE: If the clearances vary from  those  specified 
in  the  data,  the assembly  must 
be rebuilt using the 
relevant  new parts. 
!.,E .:. ...i .~ .. > . . .I 
1.. .. , 
ST1605M 
ST1603M 
45. Peen the stakc nut collar  by carefully  forming  the 
collar 
of the nut into thc slot as illustrated. 
CAUTION: A round  nose tool must  be used  for this 
operation  to avoid  splitting  the collar 
of the  nut. 
ST1604M 
46. Clean  and check high/low selector  fork  assembly 
47. To renew the selector fork remove  the  square set 
for wear 
and renew 
if necessary. 
screw  and slide 
thc fork  from the  shaft. 
.I .. ... . . ,. . .. 
Centre differential  rear bearing  track 
50. Fit the differential  rear bearing track 1,OO mm 
(0.039 in)  below the outer facc of casing  using a 
suitablc  tool as shown.  ~ ~  ~~ 
1 .OO mm (0.039 in) 
1 
50 
ST1606M 1 
Rear 
output  housing - refit 
I. Grease  output housing gasket and position on to 
99 
the rear  facc of thc transfer box casing.  
						

							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  of the  differential 
asscm bly . 
2. Locatc the differential  assembly complelc with 
selector 
fork into the transfer  box casing. It may  be 
necessary 
to rotate  the output  shaft to ease fitment, 
and  engage selector  shaft into its hole. 
ST1607M M 
3. Fit selector  shaft  ball  and spring through  the side  of 
the transfer  box casing. 
100 
4. Apply  Loctite  290 to decent plug; fit and  locate,  by 
screwing  gently fully home  and 
then unscrewing 
two  turns. 
Front  output  housing overhaul - dismantling 
1. Unscrew  seven retaining  bolts  and  washcrs  and 
remove  the differential  lock sclector side cover and 
2. Unscrew thrce retaining  bolts  and  washers  and lift 
the differential lock finger  housing and actuator 
assembly from  the front output housing. 
3. Slackcn the locknut  and unscrew  the differential 
lock  warning  light switch. 
4. Rcmovc selector  shaft dctent  plug,  spring and  ball 
using  a suitable 
magnct. 
:z->: E gasket. -- 
5. Compress  the  selector  fork spring and remove  the 
two spring retaining  caps.  
						

							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  wrench 
10. Remove  the output  flange with oil seal shield. 
NOTE: These  parts need not be separated  unless the 
flange  bolts are to be  renewed. 
11. Drift  output  shaft rearwards  from housing  using a 
soft headed mallet. 
12. Slide  off the  collar  from the output  shaft ,..;; I ., A” 
10 
4 .. .:.::.  ~ .. . . .,:.,; .. 13. Prise out and  discard 
oil  seal from output housing 
14. Remove  circlip with circlip pliers 186257. 
using service  tool 1861271. 
16. Drift  out  centre  differential  front  taper roller 
17. Drift out selector  shaft cup plug from housing. 
18. Clean  all components  ensuring all traces of 
“Loctite”  are removcd  from faccs and threads. 
19. Examine  components  for  wear or damage and 
renew 
if necessary. 
NOTE: Renew  oil seal  and  felt seal  and flange  nut. 
bcaring  track and shim. 
101  
						

							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  collar  on to the  output  shaft,  with  its 
chamfered  edge towards  the dog  teeth. 
25. 
Fit the  output  shaft through  the  bearing  and drift 
home. 
ST1614M 
Adjusting  front differential  bearing pre-load 
26. Measure  original differential  front  bearing  track 
27. 
Refit original  shim into input  housing. 
28. Drift  differential front bearing  track  into thc 
shim. 
housing.  29. 
Grease  and 
fit new gasket  and  locate  the front 
output  housing  on 
the transfer box casing. 
30. Secure  housing  with the eight  retaining  bolts and 
washers,  the  upper  middle  bolt  being  longer  than 
the  rest. 
Do not tighten  the bolts  at this  stage. 
31.  Engage  high 
or low gear. 
32.  Check 
the rolling  resistance of the differential 
using  a spring  balance  and  a length  of string  wound 
around  the exposed splines 
of the high/low hub. 
33. With  the correct  shim fitted  the load  to turn  should 
be 
1.36 kg to 4.53 kg (3 Ibs to 10 Ibs). This applies 
to  new 
or used  bearings.  (New bearings  will 
register  at the  top  end  and  used bearings 
will 
register  at the low end. 
34.  If the  reading  is  in excess  of the  above 
measurements,  remove  the  front  output  housing 
assembly  from the transfcr  box casing. 
35. Using  a  suitable cxtractor, withdraw  the  centre 
differential  bearing  track and change 
the shim  for 
one  of a  suitable  thickness. 
(A thinner shim will 
36. Fit the new  shim  and drift thc differential  bcaring 
track  back into its housing until 
fully home. 
37.  Having  obtained  the  load to turn,  prop
-up the 
transfcr  box casing on  the bench 
with the front face 
uppermost. 
~53 I .. L .. reduce the  rolling resistance). C- 
ST1616M 
38. Apply  Loctite  290 to the  threads  of the  housing 
rctaining  bolts and 
fit the eight  bolts  and  washers 
into the front  output  housing  and secure  to transfer 
box  casing. 
39. Fit front  output  flangc,  felt washers,  steel  washers 
40. Using  flange  wrench  1861205 and torque  wrench 
pull 
the output  shaft up to the correct  position. 
Check  that the 
oil seal shield  does not foul the 
and flange nu!. 
i-.. housing. &:; ...i et::;/ NOTE: Ensure that the flange  bolts are fully 
engaged  in the wrench. 
102  
						

							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 housing. 
45. Rotate  the selector shaft until the two  flats for the 
spring retaining  caps are at right  angles  to the 
side 
cover plate  face. 
, .I 
46. Compress the spring between the fork lugs and 
slide  the retaining caps 
on to the shaft ensuring the 
spring  is captured  with 
the “cupped”  side of the 
caps. 
47. Drift  selector shaft sea! cup into position. 
48. Fit selector  shaft dctcnt ball and spring in the 
tapped  hole on top 
of the output  housing. 
40. Apply  Loctite  290 to  detent  plug threads.  Screw 
detent  plug gently  homc and then  unscrew 
two 
turns. 
STI 645M 
Differential lock finger  housing  overhaul - dismantling 
1. Unscrew  and  discard the “nyloc”  nut and  remove 
2. Remove the pivot shaft from  lock finger  housing. 
3. Remove  the ‘0’ rings from the pivot  shaft  and 
4. Clean all components; examine  for wear or damage 
the operating 
lever and washer. 
housing  and discard. 
and renew 
if necessary. 
Reassembling 
5. Fit new ‘0’ rings  on to pivot shalt  and lock  finger 
6. Locate  the pivot  shaft in the housing. 
housing and lubricate 
with oil. 
103  
						

							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 cross-shaft. 
3. Drift  out selector  housing cup plug if necessary. 
4.  Clean  all the  components  and chcck  for damage 
or 
wear,  replace if necessary. 
5. Apply sealant to a new  cup plug  and fit so that the 
cup  is just  below  the 
chamfcr for  the  cross-shaft 
bore. 
6. Fit new ‘0’ ring  to cross-shaft. 
7. Lubricate  the shaft  and insert  into  the  cross-shaft 
housing. 
8. Fit selector  finger ensuring  that it aligns with the 
recess 
in the  cross-shaft. 
9. Apply  Loctite 290 to the  grub  screw and secure the 
selector  finger 
to the cross-shaft  and fully tighten  to 
thc specified  torque. 
9. Fit the differential  lock finger  housing  into its 
seating On the front output housing, ensuring (hat 
the  selector  finger is located in the flat of the 
selector shaft. 
10. Apply  Loctitc 290 to thc bolt threads and retain thc 
lock  finger  housing with the  three bolts and 
washers  to the specified  torque. 
10. Grease and fit the high/low selector  housing gasket 
on the front output  housing. 
11. Fit high/low cross-shaft housing,  ensuring  that the 
selector  finger  locates in the slot of the  selector 
shaft,  and 
secure with six bolts  and washers  to the 
specified  torque. 
r; -es! 
n/ 
ST1646M 
ST1619M 
1 04 
Input gear overhaul -dismantling 
1. Clean  the  input gear assembly  and  examine for 
wear or damage.  Remove the  bearings  only if they 
are 
to be  renewed.  
						

							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  platc on to the transfer  box 
casing  and secure  with the 
six bolts,  but do not 
tightcn. 
18. Fit the servicc tool LST105 to input  gear and 
engage  the spline. 
19. Tie a  length  of string  to the  split  pin and fit it to the 
service  tool as shown. 
20.  Attach  a spring  balance 
to the string  and  carefully 
tension  the spring  until a load 
to turn the input  gear 
is obtained.  A  pull of 2.26 kg to 6.80 kg (5 Ib to 
15 Ibs)  is required. 
21. 
If the reading  obtained  is outside the above  limits, 
the  original  shim must  be changed.  22. 
Remove the  spring balance,  string and  service 
tool. 
23. Remove  the six bolts  and the bearing  support 
24.  Drift 
out the  input  gear bearing  track from the 
25.  Select 
the correct  size shim  to obtain a load  to turn 
26. 
Fit shim  to support  plate, locate  bearing  track and 
27. 
Fit bearing  support platc  and secure  to transfer  box 
28.  Repeat  the rolling  resistance  check as previously 
plate. 
support plate and  discard original  shim. 
of 2.26 
kg to 6.80 kg (5 Ib to 15 Ibs). 
press  home. 
casing  with the six bolts  (do not tighten). 
described, and note  the value  obtained. 
Intermediate gear assembly  overhaul 
1. Drift out intermediate gear  bearing tracks 
2. Remove circlips. 
ST1628M 
3. Clean all intermcdiate  gcar components  and lock 
plate.  Check  for damage 
or wear  and replace  as 
necessary 
. 
4. Fit new  circlips  into the intermediatc gcar  cluster. 
5.  Using  tools 
LST5.50-4 and MS550 fit bcaring  tracks 
106