Land Rover Defender 90 110 Workshop 1984 Rover Manual

LT230T TRANSFER BOX 
89  

LT230T TRANSFER BOX 
90  

LT230T TRANSFER BOX 
-_ *..., ,:”:!::. . LT230T TRANSFER GEARBOX OVERHAUL 8K.:;y.:., ,. ._ .;- .... Service Tools: 
18G47-7 - Input gear cluster  bearing  cones remover/ 
replacer 
18G47RB-1 - Adaptor  centre differential  bearing 
remover 
18G47BB-3 - Adaptor  centre differential  bearing 
remover  button 
18G257 - Circlip pliers 
18G1205 -Prop flange  wrench 
18G1271 -Oil seal remover 
37 
1861422 - Mainshaft  rear oil seal replacer 
1861423 
- Adaptor/socket centre  differential  stake nut...

LT230r TRANSFER BOX 
Intermediate shaft and gear  cluster  removal 10. Remove  taper roller  bearings  and bearing  spacer 
from  the intermediate  gear cluster  assembly. 
5. Release  stake nut from recess in intermediate  shaft 
and  remove  stake nut and  discard. 
plate  at the  rear  face 
of the transfer  box. 
6. Unscrew  the single  bolt and remove  anti-rotation 
7.  Tap  the intermediate  gear shaft  from  the transfer 
box. 
10 ST1574M 
Power  take-of cover  removal 
11. Remove  six bolts  and...

LT230T TRANSFER BOX 1371 
Highhow cross-shaft housing  removal 
18. Remove the six bolts  and washers  retaining  the 
19. Remove thc gasket and cross-shaft  housing. 
cross
-shaft 
housing  and earth  lead. 
- STI 577M 
Front  output  housing  removal 
20. Remove  the eight  bolts and washers  and detach the 
output  housing  from the transfer box casing,  taking 
care  not to mislay  the dowel. 
Centre  differential  removal 
21. Remove high/low selector shaft dctent  plug, spring 
and  retrieve  the...

37 I LT230T TRANSFER BOX i 
27. Drift out differential rear bearing  track. 
28. Clean all areas of the  transfer  casing ensuring  all 
traces 
of “Loctite”  are removed  from faces  and 
threads. 
Transfer  case overhaul - re-assembling 
29. Fit studs  and dowels  to front  face of the transfer 
casing 
. 
NOTE:  The position of  the  radial  dowel blade is set 
in  line  with  the circle  which 
is formed  by the  front 
output  housing  fixing holes. 
30. Refit magnetic  drain plug with new copper...

., 
ST1588M 
95  

37 
20. Slide drive gear and spacer on to the output  shaft. 
21.  Locate  output shaft into the bearing  in 
the housing 
and  drift  into position. 
22.  Locate  speedometer  gcar (driven)  housing 
assembly  into the output  housing  and 
press in until 
flush  with 
the housing  face. 
LT230T TRANSFER BOX 
5. Remove  the high  range  gear and bush,  taking  care 
not  to disturb 
the high/low sleeve. 
6. Mark the  relationship  of the high/low sleeve to the 
hub  and then  remove  the sleeve. 
7....

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...