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. Remove the eight  retaining  bolts and lift off the 
front  differential  case. 
79. Lift off the  front  (upper)  bevel gear and thrust 
washer. 
80.  Remove  both pairs  of side  gears  with their 
respective  shafts and dished  washers  together. 
81.  Lift out the remaining  rear (lower)  bevel gear and 
thrust  washer. 
82. Remove  the rear  differential  case from the vice. 
83.  Clean  all parts,  examine  for wear  or damage, 
1 renew  as necessary. 
?. . ^... . II  ~ .,,., .. :c. .. . 
1 
w 
fG=?a 
99 - 
Obtaining 
differential  backlash by checking  bevel gear 
end
-float 
84. Using  soft jaws secure  the rear  differential  case in 
the  vice  by gripping  the inner  hub splines. 
85. Ensure  that all differential  components  are dry  to 
assist  in checking  end
-float. 
86. Using a micrometer measure one of the  bevel  gear 
thrust  washers  and note  thickness. 
87. Fit the  thrust  washer  and bevel  gear to the rear 
(lower)  differential  case. 
88. Assemble the side  gears  and dished  washers  on 
their  respective  shafts and 
fit to the  rear  case. 
89.  Measure  the remaining  bevel gear thrust  washer, 
noting  its thickness. 
90. Fit the  thrust  washer  and bevel  gear to the front 
case. 
91. Fit  and  align  the front  differential  case tightening 
the  eight  securing  bolts 
to the specified  torque. 
92.  Ensure  that the front  bevel  gear is fully  in mesh  by 
tapping 
it down,  using a punch through  the front 
differential  case. 
ST1169M W 
93. Measure  the front  bevel  gear end-float  with feeler 
gauges  through  the 
slots provided in the front 
differential  case. This must  be between 
0,25 and 
0,75 mm (0.001 and  0.003  in) maximum. 
94. Invert  differential  unit in vice and  repeat the 
above  procedure  (items 92 and 93) for the  rear 
bevel  gear in the rear  differential  case. 
95. Return the differential  unit to its  former  position 
in 
the vice i.e.  with the front  differentid  case 
uppermost. 
. I> 
ST1171M 
27  
						

							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 the other  selected thrust  washer and bevel  gear 
to  the rear case. 
102. Lubricate  all parts  with oil. 
103. Fit and  align  the front  differential  casc, locate  the 
eight  securing  bolts  and  tighten to 
the specified 
torque. 
104. Finally  check  that  the differential  gears revolve 
freely. 
105. Place the  front (outer)  differential bearing  on the 
front  differential  case and press  into position 
using  larger  end 
of tool 18G1424. 
106. Invert  the differential  unit in the  vice. 
107.  Fit the low  range  gear (largest)  to the rcar 
differential case  (with its dog  teeth  uppermost). 
108. Press  the high/low hub onto  the  splined  area of 
the case.  Check  end-float of low range  gear. See 
Data  at end 
of section. 
109.  Slide  the 
highhow selector  sleeve onto thc hub 
outer  splines, observing  the alignment  marks. 
110. 
Fit the  bush  into the high  range  (smallest)  gear 
and  slide 
the bushed  gear  onto the rear 
differential  case. 
Check end-float of high  range 
gear  and running clearance  of gear 
on bush. Scc 
data  at end of section. 
NOTE: 
If the  clearances  vary considerably  from 
those  specified  in the  data  the assembly  must be 
rebuilt. 
111.  Place  the  rear differential  bearing on the  rear 
diffcrcntial  case  and press 
into position  using the 
smaller  end of tool  1861424. 
28 
.,:;::- 0 -U 
112. Fit the stake nut using  tool 1861423 and  tighten 
to the specified  torque. 
113. Peen the nut flange into the slot provided. 
114. 
Remove  the differential  unit from  the vice. 
115.  Lubricate  gears,  bearings,  sleeve  and bush with 
oil. 
116. Clean  and check the high/low selector fork 
assembly  for wear  and rencw if necessary. 
117. 
To renew  the  selector fork  remove the square  set 
screw  retaining 
it to the selector  shaft  and  ensure 
any  traces  of Loctite  are removed  from the 
threads. 
118. Refit  the selector fork with the  fork  boss  towards 
the  three  detent  grooves.  Align 
thc hole in the 
fork  boss  with the  indent 
in the shaft  nearest  to 
the  detent  grooves. 
119.  Apply  Loctite  290 to the  set screw  threads and 
fit 
the set screw to  the correct torque. 
120. Prop up the  transfer  box so that its front side is 
uppermost. 
121. Fit the selector  fork to the high/low selector 
122.  Locate  the  differential  assembly  and 
highllow .- 
selector fork assembly  into  the transfer  casc.  It 
may  be  necessary  to  rotate  the  output  shaft 
to 
ease fitment. 
123. Fit the selector  shaft detent  ball and  spring,  apply 
Loctite 
290 to the detent  plug threads,  screw in 
the detent  plug until  the spring  is just  coil bound, 
then back  off two  complete turns. 
e;?-. - .. 
42: 
g.. ... . sleeve in the differential assembly. -, ,.., 
ST1190M  
						

							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 
129. Compress  the selector fork spring  inside  the 
130.  Slide  the sclcctor  shaft out 
of the rear  of the 
131. Remove the selector fork and spring through the 
132.  Lift out dog sleeve  from the back of the output 
.I,.. . .. I 
housing  and slide  out the spring  locating C caps. 
housing. 
side  cover  aperture. 
shaft housing. 
flange  nut, steel  and 
felt washers. A two-legged 
puller  may be necessary. 
NOTE:  Ensure that flange  bolts are fully  engaged 
lock finger housing and lift Out the complete 133. Using the flange wrench 18G1205 remove [he assembly. 
126 in the  wrench. 
134.  Remove the output  shaft flange with oil seal 
e9 
shield. 
ST1 I73M 
127.  Slacken the  lock nut retaining the differential  lock 
switch  and unscrew  the switch. 
127, -1 d-- 128 / 
NOTE:  These parts need not be separated  unless 
the  flange 
bolts are to be renewed. 
135.  Drift the front  output  shaft  rearwards out of the 
housing. 
136.  Slide  off the  collar  from the 
output shaft. 
137.  Prise 
out and  discard 
thc oil seal(s), using  service 
29  
						

							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 the  housing. Do not 
use  excessive  force, 
if necessary, warm the 
housing assembly  and case. 
144. 
Fit the  bearing retaining circlip,  using circlip pliers 
186257. 
145. 
Fit a  new  dual  lip oil seal (open  side inward)  until 
the  seal  is 
in contact  with the bearing  circlip. It is 
essential 
to use  replacer  tool 1861422. 
NOTE: On early  production  two separate  seals 
were  used,  these should  be replaced  with the new 
dual  lip seal. 
- -- STSOSM 
146.  Carefully  charge the lips  of the  seal  with  grease. 
147.  Slide the  collar onto the front  of the  output  shaft 
148.  Fit 
the output  shaft through  the back of the 
149.  Examine  the flange  seal  track  to check  for  any 
with  its 
chamfered  edge 
to the front. 
housing. 
damage that  may harm  the seal. 
Obtaining  bearing pre-load 
150. Measure  the original  differential  front  bearing 
151. Refit the original  shim. 
152. Drift the  differential  front bearing  track  into the 
housing. 
153.  Grease  and 
fit a new gasket  and  locate the front 
output  shaft housing  on the  transfer  box. 
154.  Loosely  retain the 
h. ,sing with the eight securing 
bolts  (with  spring 
w,~ ners),  the upper  middle bolt 
is  longer. 
Do not i:illy tighten  the bolts  at this 
stage.  track 
shim,  noting  its thickness. 
30 
155.  Engage  high or low gear. 
156. Check the rolling  resistance  of the  differential, 
using  a spring balance  and a piece 
of string  wound 
around  the  exposed  splines 
on the high/low hub. 
Little 
or no resistance will  register. 
157. Tighten  the bolts  a little  at a  time,  occasionally 
checking  the rolling  resistance.  With the correct 
shim  selected  and 
the bolts  tightened to thc 
specified torque a pull of 1,s to 4,5 Kg (4 to 10 Ib) 
is  required  on the  spring  balance.  This applies  to 
new 
or used bearings. 
158.  If the  reading  is outside  the 
abovc limits remove 
the  front  output  shaft housing  assembly  from  the 
transfer  case. 
159. Using a suitable  extractor,  withdraw the front 
differential  bearing  cup from  the  housing and 
exchange  the shim  for one  of suitable  thickness. 
160.  Rcfit  the bearing  cup. 
161. Having  obtained  the  corrcct  rolling  resistance 
prop
-up  the  transfer  box on the bench with thc 
front  sidc uppermost. 
162.  Grease  and 
fit the  front  output shatt housing 
gasket  and locate  the housing 
on the transfer  box. 
163.  Apply  Loctite  290 to the  threads  of the  housing 
securing  bolts and 
fit the eight  securing bolts (with 
spring washers).  Note that  the  upper middle  bolt 
is  longer. 
164. 
Turn the  transfer  box into its  normal operating 
position. 
165. 
Fit both  input  and output  flanges as  follows. 
166. Using  flange  wrench 18G1205 and a torque 
wrench 
pull up  output  shaft to corrcct  position. 
Check  that  the 
oil seal shield  does not foul the 
housing 
. 
NOTE: Ensure  that flange  bolts are fully  engaged 
in the wrench.  
						

							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 
the back,  grooved  (detents)  end 
last,  and pass 
it through the selector  fork lugs and 
spring  and into  the front  of the  housing. 
171.  Rotate  the  selector shaft until  the  two flats  are 
uppermost. 
172.  Compress 
the spring  slightly between the fork lugs 
and fit the two locating  ‘C’ caps. 
17.5 & 
173. Fit the selector shaft  detent ball and spring via the 
tapped  hole  in the  top  of the housing. 
174.  Apply  Loctite  290 
to the  detent  plug threads, 
screw 
in the  detent  plug until  the spring  is just  coil 
bound,  then back 
off two complete  turns. 
175.  Loosely 
fit the differential  lock  switch in the 
tapped hole on top  of the  housing,  leaving the 
locknut  loose  for adjustment. 
176.  Grease  and 
fit the differential  lock selector  side 
cover 
gasket and fit the  side  cover,  securing it with 
the seven  bolts (with spring washers). 
Differential  lock finger  housing - Overhaul 
(Instructions 
177 to 183) 
Dismantling 
177. Remove  and discard thc Nyloc nut and release  the 
lock  lever  and selector  ‘finger’ from the ‘finger’ 
housing. 
178.  Remove  and  discard the 
‘0’ rings from  the 
selector  finger and the selector  finger housing. 
179.  Clean  remaining  parts, examine  for wear 
or 
damage,  renew as  necessary. 
STll79M 
Reassem bly 
180. Fit new ‘0’ rings to the finger  housing  and 
selector  finger and lubricate  with oil. 
181.  Locate the selector finger 
in thc finger  housing. 
182.  Fit  the differential  lock lever  over the flats 
on the 
selector  finger 
so that it will face  forward in the 
operating position. 
183. Fit the plain  washer  and a ncw Nyloc  nut. 
184. Fit the differential  lock  ‘finger’ housing  assembly 
into  the  round  aperture 
in the front  output  shaft 
housing locating 
the selector  ‘finger’ on the flat on 
the selector shaft  inside the housing. 
185.  Apply  Loctite  290 
to the ‘finger’  housing  screw 
threads  and 
fit the three securing  screws (with 
spring washers)  to 
the correct torque. 
186.  Grease  and 
fit the differential  lock selector  side 
cover gasket  and fit the  side cover,  securing it 
with 
the seven bolts  (with spring  washers). 
187. Using a screwdriver  inside the housing  move the 
high/low selector  shaft  rearwards (i.e. into high 
range  position)  to provide  access 
for fitting the 
yoke over the end of the selector shaft. 
188. Locate the yoke  on the  selector  shaft,  apply 
iociiie 290 to the yoke set screw and fit iitc screw 
to the specified  torque. 
31  
						

							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 
rcmoving the retaining set scrcw. 
195. Clean  parts  ensuring that all traces of Loctite  are 
removed,  examine  for  wear or damage,  renew  as 
necessary. 
Reassembling 
106. Fit the ‘0’ ring  to the  operating  arm end of the 
197.  Locate operating arm 
on the shaft  blind hole. 
198. Apply  Loctite  290 to the operating  arm  set scrcw 
199. Locate the selector  fork inside  the housing. 
200.  Slidc  the  cross  shaft into the housing  passing  it 
through  the selector  fork. 
201. 
Fit thc ‘0’ ring to the  fork  end of the cross  shaft 
(inside 
the housing)  and lubricate  both ‘0’ rings. 
202.  Position  the cross  shaft fully home. 
203.  Locate 
the selector fork 
on the  shaft  blind  hole. 
204.  Apply  Loctite  290 
to the fork  grub  screw  threads 
and 
fit the grub  screw. 
205. 
Fit the  circlip  on the  end of the cross shaft. 
206.  Grease  and 
fit the gasket to the highhow selector 
housing  aperture  on 
the front output  shaft 
housing. 
207.  Position  the 
highhow selector  housing so that the 
projecting  selector fork engages  the yoke  side pins 
inside the housing. 
208.  Fit the  six selector  housing  retaining  bolts (with 
spring  washers). 
209. 
Prop  up the  transfer  box  on the  bench  with  front 
side  uppermost. 
32 
cross  shaft. 
threads  and 
fit the set screw.  210. 
Fit the  oil seal  into 
the front of the transfer box 
(seal  lip to rear  of case)  using  replacer  tool 
18G 1422. 
211. Prop up the  transfer box on  the  bench  with  rear 
side uppermost. 
212.  Drift in the  input  gear front  bcaring  track  from 
inside  the back  of the  transfer  box, using  a 
suitable  punch. 
Input gear - Overhaul 
(Instructions 
231 to 237) 
Dismantling 
213.  Clean  all parts,  examine for wear  and damage, 
renew  as  necessary.  Remove  the bearings only 
if 
they are to be renewed. 
214. 
Secure  hand  press MS47 in vice and  using  collars 
and buttons 
18647-7 remove  the front taper roller 
bearing  from the input  gear assembly. 
215.  Reverse  input gear assembly 
in hand  press  and 
rcmove the rear taper roller bearing. 
216. 
Remove  the hand  press from the vice. 
ST1184M II I 
Reassem  bly 
217. Locate thc front  taper  roller  bearing  on the input 
- ;;” 
gear assembly  and press  the bearing  fully home.  
						

							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 the  original shim  to the  main  bearing housing. 
225.  Locate 
the rear bearing  cup  on the  main  bearing 
226.  Apply  grease  to the  gasket  and 
fit onto the 
2
-27. Fit the  main  bearing  housing  and  tighten the two 
remove 
the shim  behind 
it. 
original  shim, noting  its thickness. 
housing  and press 
it fully home. 
t ransfcr  box casing . 
securing screws to the specified  torque. 
- .. ; Y!!:!. .. . ., .. I ... . , . 1. 
i. .. .I . , .,... . ... . .I. . ... 
228. Wind sllfficienr striflg around the gear !W!h (0 
rotate the input  gear. A pull  of  1,4 to 3,6 Kg (3 to 
8 Ib) is required  on  the  spring balance.  This 
applies  to new 
or used  bearings.  229. 
If the  reading  obtained is outside  the  above 
limits  the original  shim  must be changed 
accordingly. 
230.  Remove 
the two screws  retaining  the mainshaft 
bearing housing. 
231.  Press  out the rear  bearing  cup from  the  bearing 
housing  and remove  and discard 
the original  shim. 
232.  Select  a shim 
to the  required  thickness  to obtain 
the correct  pre-load of 0,02 to 0,07 mm (0.001 to 
0.003  in) on reassembly. 
233. 
Fit the shim  to the  main  bearing  housing and then 
press the  rear bearing  cup into  position. 
234. 
Fit the  main  bearing  housing  and tighten  the  two 
securing screws 
to the  specified  torque. 
235.  Grease  and 
fit P.T.O.  cover gasket  and  finally fit 
the P.T.O.  cover securing it with six bolts  (with 
plain  washers) 
to the specified  torque. 
Intermediate gear  assembly - Keassembly 
236.  First I-emovc the needle  roller bearings and  spacer 
from  the gcar assembly. 
237.  Clean  the parts,  including  the thrust  washers  and 
lock  plate  and examine  for  wear 
or damage, 
renew  as  necessary.  Refer to DATA  at end 
of 
section for thrust  washer  thickness. 
238. 
Fit the 0 ring  to the intermediate  shaft. 
239. 
Fit the 0 ring  into the front  of the transfer case. 
240.  Lubricate  thrust  washers,  bearings, shaft and 
241.  Fit  needle bearings  with spacer  interposed. 
spacer. 
If  the bearings  have plastic cages,  the flangcd 
cnd 
of each  cage must face  the thrust  washers,  when 
fitted. 
242. 
Fit front  thrust  washer  to slot  in transfer  (plain 
side  to case). 
243.  Locate  gear assembly  partially 
into the  transfer 
case 
so that it rests  on the  front thrust  washer. 
244.  Locate  rear thrust  washer  (plain side uppermost) 
into  slot in transfer  case. 
245.  Gently push  gear assembly into  mesh. 
246.  Using  a screwdriver  through  the  intermediate 
shaft  hole guide  the locating  tab on the  rear thrust 
washer into the slot  provided 
in the transfer  case. 
247.  Align  gear and thrust  assembly  and slide  the 
intermediate  shaft into  the  transfer box  from  the 
rear. 
248. Align  the  shaft so that  the  lock plate  slot in the 
end is on top. 
?. ./ .I.... . .. . ,. .?, . NOTE: The  pre-load  can only  be measured  while 
the  Transfer  gearbox 
is separated  from the main 
gear 
box.  
						

							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. Clean and fit the bottom cover,  using the ten bolts 
bolts 
only. 
(with  spring washers). 
Transmission  brake assembly 
254. Clean  brake backplate  and oil drip  plate  and 
apply  silicone  rubber sealant.  Locate  the 
backpiate on the rear  output shairispeedometer 
housing so that the brake operating  lever is on the 
right
-side  rear. 
255. 
Fit the  four  Brako  Durlok  bolts, the lower  two 
with plain washers,  also  retain the oil drip  plate. 
Tighten 
to specified  torque. 
256.  Clean  and 
fit brake  drum  and fit the two 
countersunk  retaining screws. 
34 
257,261 259 258-   I 
Highhow gear  change  housing - Overhaul 
(Instructions 
262 to 298) 
Dismantling 
262.  Remove  the split  pin from  the clevis pin  at the  top 
of  the  differential  lock cross  shaft lever  which 
secures  it 
to the gear change  cross shaft. 
263.  Remove  the  washer and clevis  pin and  the 
anti- 
rattle  nylon  strip. 
264.  Mark  the  position  of the 
high/low gcar  change 
operating  arm on the  splined  shaft of 
the gcar 
change  crank arm. 
265.  Slacken  the clamp  bolt and remove  the operating 
arm. 
266.  Remove  the  four bolts from  the  top  of the  gear 
change  housing  and 
iift off the grommet piate 
grommet,  gate plate and gasket. 
267.  Remove the  split pin from 
the gear  change  crank 
arm  clevis pin  and remove  the clevis  pin. 
268.  Remove the  circlip from 
the highilow gear change 
lever bush. 
269.  Withdraw the gear change lever  from the housing, 
with  ball  and 
socket bush. 
Differential  lock switch  adjustment 
257. Select  differential  locked  position by moving  the 
differential  lock lever  towards  the right  side of the 
transfer  box. 
258.  Obtain a battery  and connect 
a test  lamp circuit  to 
the  differential  lock switch. 
259. Slacken  the lock  nut  off  and screw in the lock 
switch 
until the  bulb  is illuminated. 
260.  Turn  the lock switch  another half  turn 
and tighten 
the  lock  nut against 
the housing. 
261.  Disconnect 
the battery  and move  the differential 
lock  lever  towards  the left  side  of the transfer  box 
to disengage the differential lock.  
						

							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. 
281.  Lubricate 
‘0’ rings with oil. 
282.  Clip  the detent  spring onto the detent  plate. 
283.  Fit detent  plate  assembly into housing  and retain 
from  outside  with two Nyloc  nuts 
(with plain 
washers). 
284.  Compress 
thc detent  spring and fit the  gear 
change crank  arm 
in the housing. 
285. 
Fit cross  shaft  into  position  locating  end in the 
crank  arm. 
286.  Fit  the housing  end cover  to support the other  end 
of  the  cross  shaft. 
287.  Finally  secure the  housing end cover  with the two 
countersunk  screws. 
288.  Before  refitting  the gear  change  lever remove  the 
clevis  pin bushes  and  the Nylon  socket  bush  and 
ball. 
289.  Clean all parts,  examine  for wear or damage, 
renew as necessary. 
290. Fit  and  grease  gear lever  ball and  Nylon  socket 
bush  to gear  lever. 
291.  Fit and  grease  clcvis pin bushes. 
292.  Locatc  gear change  lever assembly 
in cross  shaft 
(do  not 
fit socket  bush  retaining  circlip at this 
stage). 
293.  Align  gear change  lever  end with  crank  arm fork 
ensuring 
that the  gear  lever  is crankcd rcarwards 
and fit clcvis and split  pin. 
294.  Finally  secure Nylon socket  bush with circlip. 
295.  Grease  and 
fit gasket to gear change  housing face. 
296. 
Fit the gate plate. 
297.  Fit the grommet. 
298. 
Fit the  grommet  plate  and  retain with the  four 
securing bolts (with  spring washers). 
275.  Remove 
the two ‘0’ rings  from  the crank arm. 
276.  Remove and  discard the two  Nyloc  nuts retaining 
277.  Remove  the detent  plate  and  spring  from the 
278.  Clean 
all parts, examine for wear or damage, 
the detent 
plate. 
housing. 
renew  as necessary. 
35  
						

							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  bolt 
and 
fit the  operating  arm on to the  splined  shaft 
projecting  from the 
high/low gear change 
housing,  carefully  aligning 
it to the  marks on both 
camponents. 
303.  Tighten  the clamp  bolt to the specified  torque. 
304.  Before  refitting  the differential  lock cross  shaft 
lever  and pivot  bracket  remove the respective 
clevis  pins and Nylon  bushes. 
Also remove  the 
split  pin retaining  the cranked  lever and 
disconnect  it. Clean  and examine  for wear 
or 
damage,  renew as necessary. 
305.- Fit the  cranked  lever to the bottom of thc cross 
shaft  lever and secure  with a new  split  pin (with 
plain  washer). 
NOTE: 
Early  gearboxes  were fitted  with a short 
connecting  link secured  by a ‘Nyloc’  nut. 
II 
306. Grease  and fit the Nylon bushes to the middle 
pivot of the  cross  shaft  lever. 
307. 
Fit the  cross  shaft  lever  to the (loose)  pivot 
bracket  with the clevis  pin, washer  and split  pin. 
308.  Fit the  cross  shaft  lever  fork (top)  to 
thc gear 
change  cross shaft. 
309.  Locate  the anti
-rattle Nylon strip  and fit the clevis 
pin,  plain  washer  and split  pin. 
310.  Fit the  cranked  lever, 
at thc bottom of the 
differential  lock cross  shaft lever,  to the  lock  lever 
and  retain  the clevis  pin and  plain  washer  with a 
new  split  pin. 
311.  Grease  and 
fit the Nylon  bushes  to the  operating 
arm  on the  selector  housing  cross shaft. 
Adjustment of highllow connecting  rod 
312. 
313. 
314. 
315. 
316. 
317. 
318. 
319. 
36 
This  operation  is carried  out in situ or on the 
bench,  after assembly  to the  main  gearbox. 
Remove  the 
four bolts from the top  of the  gear 
changc  housing  and 
lift off the gear changc  lever 
grommet  plate and the gcar  change  lever 
grommet.  Replace the four  bolts 
tcmporarily to 
retain  the gate  plate  in position. 
Check  that 
the gear lever  does not foul the gate 
plate  when  high or low  range  is selected. 
If 
adjustment  is required  carry out the following 
procedure.  *Slacken  off the  connecting  rod locknuts. 
Move  gear change  lever into high  range 
(rearwards)  and move  the operating  arm 
on the 
selector housing cross shaft into high  range 
(forwards). 
Tighten 
locknut(s). 
Check  that the gear  change  lever does not foul  the 
gate  plate 
in this position. 
Engage  and check  low range  in the  same  way.  320. 
After  adjustment  return the gear  change  lever to 
the  high  range  position. 
321.  Remove  the four  bolts  retaining  the gate  plate  and 
refit  the grommet  and grommet  plate. 
322.  Refit  the four  bolts  (with  spring  washers). 
* On early versions of the transfer  gearbox  a different 
connecting  rod fork  end was  used 
with a single 
locknut. 
In this  case  the following  method of 
adjustment  is recommended. 
(a)  Disconnect 
the top of the  differential  lock 
cross  shaft lever  from the gear  change  cross 
shaft. 
(b)  Remove  the four  bolts  retaining  the gear 
change  housing  to the 
remote gear  change 
housing 
on the main  gearbox. 
(c)  Lift  up the  housing  assembly  (with the 
connecting  rod attached)  and rotate 
it as 
required 
to vary  the length  of the connecting 
rod. 
Transfer  box mounting - Refitting 
323.  Fit the rubber  mounting  plate to the  right  sidc of 
the  front  output  housing  by fitting  the 
four 
securing  bolts (with  new lock  tabs). 
Handbrake  linkage - Refitting 
324. Locate  the handbrake  linkage bracket in position 
on the right  hand  side of the  transfer  box casing 
and  secure 
as follows. 
325.  Fit the  two  bolts  (with  spring  washers)  and 
distance  pieces to retain  the front  sidc 
of the 
linkage  bracket. 
ST 
326. Fit the  two  bolts  (with  spring  washers)  to secure 
the  rear  end 
of the linkage  bracket.  The lower 
bolt  is shorter. 
327. 
Insert the  clevis  pin through the brake  operating 
lever, 
fit the  handbrake  link, plain  washer  and 
split  pin. 
. :/