Land Rover Defender 90 110 Workshop 1984 Rover Manual

							LT230R TRANSFER GEARBOX 137 I 
. _..._ _(-.-_ ,,..j .* _.. 1_...  .I 
15. Locate rear thrust  washer  (plain side uppermost) 
16.  Gently  push gear assembly 
into mesh. 
17. Using  a screwdriver  through the intermediate  shaft 
hole  guide 
thc locating  tab on the rear  thrust 
washer 
into the  slot  provided in the transfer  case. 
18. Align gear and thrust  assembly  and slide the 
intermediate  shaft into the transfer  box from the 
rear. 
19. Align the shaft so that  the lock  plate in the end is 
on top. 
20.  Apply  Loctite 
290 to the  lock  plate  bolt threads. 
Locate  lock plate  into position  and 
fit securing  bolt 
(with  spring  washer). 
21.  Lever  the 
gear.assembly to one  side  and measure 
the  end
-float with feeler  gauges.  This should  be 
between 
0,08 and 0,35 mm (0.003  and 0.014  in). 
22.  Grease  and 
fit the bottom  cover joint washer. 
23.  Apply  Loctite  290 to the  ten 
bolts and  evenly  ~ 
tighten to 22 to 28 Nm (16 
to 21 Ibf ft). 
24, 
Fit the  oil catcher  to the  brake  plate, using silicone 
rubber  sealant  and secure  the backplate  with the 
four  bolts.  The 
two bolts securing  the oil catcher 
are  fitted 
with plain  washers. 
25. Fit the  brake  drum and retain  with the two  screws. 
26.  Connect  the rear  prop  shaft. 
27. Refill the transfer  box with  the correct  oil. 
into 
slot in transfer 
case. 
T . ..  ... .. .. :., ,. 
. :. , : L.: ,. .... . ... . I .. 
19  
						

							LT230R TRANSFER GEARBOX 
OVERHAUL LT230R TRANSFER GEARBOX 
Service tools: 
RO 605862 - Intermediate  shaft removal 
18G1273 - Sed1 remover  arm. 
18G1205 - Flange wrench 
18G257 - Circlip pliers  linkage. 
18G1422 - Oil seal  replacer 
18G1423 -Stake  nut remover 
MS47 - Hand  press 
18G47BB/1- Collars 
18G47BB/3 -Button 
18G47BB/2 - Collars 
1801424 - Differential  centre bearing  drift 
18G47-7 - Collars and buttons 
LST 47-1 - Collars 
REMOVE 
ASSEMBLIES FOR  OVERHAUL 
(Instructions 
1 to 33) 
6. Disconnect  the bottom of the high/low connecting 
rod  from  the 
high/low operating  arm by removing 
the  split  pin and  clevis  pin. 
7. Remove  the plastic  bushes  from the operating 
8. Remove  the gearchange  housing complete with 
8 
1. Having  removed  the complete  gearbox and 
transfer  box assembly.  The transfer  box 
is 
separated  from the gearbox  on the  work  bench. 
NOTE:  To facilitate  removal of various  items on 
the  work  bench,  obtain suitable  wooden blocks to 
enable  the transfer  box 
to be turned  and propped 
up 
as required. 
Hand  brake  linkage  removal 
2. Remove  the split  pin and  clevis  pin to release  the 
handbrake  linkage from the brake  operating 
lever. 
3. Remove  the two  bolts  (with  spring  washers) 
securing 
the rear  end of the handbrake  mounting 
bracket 
to the  casing,  the lower  bolt is shorter. 
4. Remove  the two  bolts  (with  spring  washers  and 
distance  pieces) securing  the front  sidc 
of the 
handbrake  mounting bracket and remove  from 
the  transfer  box. 
Transfer 
box mounting  removal 
5. Remove the bolts  retaining  the right  hand  rubber 
mounting  plate. 
20  
						

							~~230~ TRANSFER GEARBOX 137 I 
GENERAL ARRANGEMENT OF LT230R TRANSFER  GEARBOX 
4 
21  
						

							. 
LT230R TRANSFER GEARBOX 
GENERAL ARRANGEMENT  OF TRANSFER  GEARCHANGE  HOUSING 
1. Main selcctor  lever. 
2. Transfer  gear selector  assembly. 
3. Differential lock selector assembly. 
ST886M 
1 - 5 
f; 
P -* ‘J 
22  
						

							LT230R TRANSFER GEARBOX 1371 
Transmission  brake removal 
9. Remove  the  two  countersunk  brake  drum 
10. Removc the four bolts  securing  the  brake 
retaining screws 
and 
pull off the  drum. 
backplate,  two 
of these also retain the oil catcher. 
NOTE: An hexagonal  type socket  should  be used 
for  these  bolts. 
Bottom  cover removal 
11. Hemove the ten  bolts  retaining  the bottom  cover. 
Intermediate  shaft removal 
12. Remove  the shaft  lock  plate  retained by a single 
bolt  at the  rear  face of the transfer  box. 
13. Withdraw the intermediate  shaft,  using a screw 
driver  in 
the slotted  end. Where  the shaft  cannot 
be  easily  withdrawn use extractor 
R0605862. 
14. Lift  out  the  intermediate  gear  cluster, roller 
15. Remove the thrust washers. 
16. Remove  the 0 ring from  the intermediate  shaft 
and  the transfer  box case. 
bearings 
and spacer. ST 1 
Power take off cover  removal 
17. Remove  the  four bolts  retaining  the circular 
P.T.O. cover  and the speedometer  cable clip 
plate. 
18. Removc  the gasket. 
NOTE:  The other  two bolts  were removed  with the 
gearbox  assembly  cradle.  
						

							(371 ~~230~ TRANSFER GEARBOX 
Input gear removal  30. Remove  the centre  differential  unit with  the 
selector 
shaft/fork assembly. 
19.  Remove  the two  countersunk  screws and release 
the  mainshaft  bearing housing. 
20. Remove the gasket. 
21.  Remove  the input  gear assembly. 
22.  Prise  out and  discard  the oil seal  at the  front  of the 
transfer  case using  service  tool 
1861271. 
23. Drift out the input  gear front  bearing  track. 
Highhow selector housing  removal 
24.  Remove 
the six  bolts to release  the selector 
25.  Remove  the gasket. 
housing. 
Front  output  shaft housing  removal 
26.  Slacken  the square  headed  set screw  securing  the 
yoke to the high/low selector  shaft inside the 
highhow selector  housing  aperture. 
27. If necessary  use a screw driver to move the 
selector  shaft rearwards  and allow 
thc yoke to be 
lifted  out. 
28.  Remove  the eight  bolts 
to release  the front  output 
shaft  housing  assembly. 
The upper middle  bolt is 
longer. 
NOTE: The  ‘radial’  dowel in the  transfer  box face 
should  not be disturbed. 
Centre  differential  removal 
29.  Remove  the 
high/low selector shaft detent  plug, 
spring  and ball. 
NOTE:  The ball may  be more  easily  retrieved  from 
inside  the transfer  case after  the selector  shaft is 
taken  out. 
24 
ST1165M 
4z-L rl. Rear output  shaft housing  assembly  removal *:a. ..bi’ 31. Remove the six screws to relcase the  housing.  The 
32.  Remove  the gasket. 
upper 
screw is longer. 
NOTE:  Removal  of the  above  housing  will reveal 
the  centre  differential  rear bearing  track in the 
transfer  box casing.  Before drifting  out, either 
unscrew  the two  studs  and radial  dowel projecting 
from  the transfer  box front  face or use  suitable 
wooden  blocks to support  the box 
to avoid  damage 
to  these  items. 
33. Drift out the differential  rear bearing  track. 
NOTE:  If it is  required  to completely  strip down 
the  transfer  box to the  basic  casting,  remove the 
level,  filler and drain  plugs. 
IMPORTANT:  Clean all parts  ensuring  any traces 
of  Loctite  are removed  from faces and threads. 
Ensure  that the magnetic  drain plug 
is thoroughly 
cleaned.  Renew 
oil seals and examine  all other 
parts  for wear 
or damage, renew  as necessary. 
f-, --.  
						

							LT230R TRANSFER GEARBOX 1371 
Reassembling 
34. Ensure  that all faces of the transfer  box are clean. 
35. Check  that level/filler and drain  plugs  are in 
position. 
36.  Fit 
the two  studs  which  are used for part  retention 
of  the  extension housing. 
37.  Screw 
in the ‘radial’  dowel. It is important  that its 
projecting  blade is set 
radially in line with the 
tapped  fixing hole centres 
in the transfer  box 
casing.  46. 
Remove  the speedometer  driven gear and spindle 
47.  Remove  the 
‘0’ ring and oil seal. 
from 
the spindle  housing. 
n 
Rear output  shaft housing - Overhaul  (Instructions 47 
to 73) 
Dismantling 
38. Using flange  wrench 1861205 remove  the flange 
nut. steel  and felt washers. 
NOTE:  Ensure flange bolts are fully  engaged  in the 
wrench. 
h 38 48.  Slide  off the  spacer  and speedometer  drive gear 
from  the output  shaft. 
49.  Clean 
all parts,  renew oil seals and Nyloc  flange 
nut  and  examine  all 
other parts for wear or 
damage,  renew as necessary. 
Reassembling 
50. Press the output  bearing  into the housing.  Do not 
use  excessive  force. If necessary  warm the housing 
and  case. 
51. Fit the bearing  retaining  circlip using circlip  pliers 
186257. 
52. 
Fit a new  dual  lip oil  seal (open  side inward),  with 
the  seal  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. 
39.  Remove  the output  shaft flange  with circlip 
attached.  If necessary,  use a two
-legged  puller. 
NOTE:  The circlip  need only be released  if the 
flange  bolts are to be  renewed. 
40.  Remove  the speedometer  spindle housing.  This 
can  be prised  out with 
a screw  driver. 
41.  Remove  assembly  from vice and support  the 
housing  to allow  removal 
of the shaft,  drifting it 
out by striking  the flange  end of the shaft. 
driver 
in the slot provided. 
18G 1271. 
retaining  the bearing. 
housing. 00 52 
42. CarefL!!!y prise nff the oi! catch ring llsing 2 screw 
43.  Prise  out and  discard  the seal(s) using tool 
44.  Using  circlip  pliers 
18G257 remove  the circlip 
45.  Drift  out the bearing  from the back  of 
the ST903 M 
25  
						

							(37 I LT230R TRANSFER GEARBOX 
53. Carefully charge the lips  of the  seal with  grease. 
54. Fit oil catch  ring on to  housing. 
55. Fit oil seal  into  speedometer  spindle  housing 
(open  side inwards)  with a suitable 
tubc. 
56. Fit ‘0’ ring  to speedometer  spindle housing. 
57.  Lubricate  seal and 
‘0’ ring with oil. 
58. Locate  speedometcr  driven gear and  spindle in 
spindle  housing  and push into  position. 
59. Slide speedometcr  drive gear and spacer  onto 
output  shaft. 
60. Fit output  shaft  to the  bearing in the rear  output 
shaft  housing. 
61. Examine the flange  seal  track  to check  for  any 
damage that  may harm  the seal. Retain  for fitting 
later. 
62. Locate  speedometer  spindle housing  assembly in 
the output  shaft  housing  and  push  in flush with 
housing face. 
-NOTE: Before  fitting the rear  output  shaft housing 
to  the  transfer  box casing  the  centre  differential 
rear  bearing  track must be fitted. 
63.  Drift  the centre  differential  rear bcaring track into 
the  transfer  box casing 
1,5 mm (:,; in) below  the 
outer  face of the  casing.  Check the depth  before 
proceeding. 
Fitting  rear output  shaft housing  to transfer  box 
64. Grease  and fit housing  gasket  and locate  the 
housing 
in position on the  transfer  box. 
NOTE: If the  differential  rear main  bearing  track 
has  been  correctly  fitted there will be a gap 
between  the housing  face and the gasket  at this 
stage. 
65. Apply Loctite  290 to the threads of the six housing 
securing  screws,  noting  that the upper  screw is 
longer. 
Fit the  screws  (with spring  washcrs) 
evenly  tightening  them to the  specified  torquc. 
This  will press 
in thc rear  main  bearing  track to 
the  correct  position  and seat 
thc housi3g. 
Centre  differential  Unit - Overhaul 
(Instructions 
66 to 119) 
Dismantling 
66. Detach the high/low selector  shaft and fork. 
ST1189M I1 I I II I 
67. Using  soft jaws  secure  the differential  unit in a vice 
with the ‘stake’ nut  uppermost. 
68. Remove the peened-ovcr metal to facilitatc 
removal of the nut. 
69. Remove  the ‘stake’  nut using tool 18G1423. 
70. Remove  the differential  unit from  the vice. 
71. Secure  hand press MS47 in vice with  collars 
18G47BB/1 and using  button 18G47BB/3 remove 
rear taper (twenty
-four)  roller  bearing  and collars 
LST 
47-1 for  latest  (twenty-three) roller  bearing. 
72.  Substituting  collars 
18G47BW2 remove  front 
taper  roller  bearing. 
73. 
Remove  the hand  press  from the vice. 
STl166M ii i 
74.  Remove  the  high range  (smallest)  differential f=:. gear and its bush. ’ d 75.  Mark  the relationship of the highhow selector 
sleeve 
to the  hub  and remove the  sleeve. 
26  
						

							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