Land Rover Defender 90 110 Workshop 1984 Rover Manual
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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 remover/replacer 18G 1424 - Centre differential bearing replacer MS47 -Hand press MS550 - Bearing and oii seal replacer handle LST47 -1- Adaptor centre differential bearing remover LST104 -Intermediate gear dummy shaft LST105 - Input gear mandrel LST550-4 - Intermediate gear bearing replacer L TRANSFER BOX DATA Front bevcl gcar end-float ......................... Rear bevel gear end-float .......................... Rcar output housing clearance ..................... High range gear end-float ......................... Front differential bearing prc-load .................. Input gear bearing pre-load ........................ Intermediate shaft bearing pre-load ................. 0,025 to 0,075 mm (0.001 to 0.003 in) 0,025 to 0,075 mm (0.001 to 0.003 in) 1,OO mm (0.039 in) 0,05 to 0,15 mm (0.002 to 0.006 in) 1.36 to 4.53 kg (3 to 10 Ibs) 2.26 to 6.80 kg (5 to 15 Ibs) 1.81 to 4.53 kg (4 to 10 Ibs) Transmission brake removal (if not previously Bottom cover removal removed) 3. Rcmove the six bolts and washers retaining thc 4. Remove the gasket and bottom cover. 1. Remove two countersunk screws and withdraw bottom cover. 2. Remove four bolts securing the brake back-plate; brake drum. the two bottom fixing retain the oil catcher. NOTE: An hexagonal type socket should be used for these bolts. ST 91
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 washers retaining the take- 12. Remove the gasket and cover. off cover and speedo cable clips. // f-- , Input gear removal 13. Remove the two countersunk screws and detach the main shaft bearing housing. 14. Remove the gasket. 15. Withdraw the input gear assembly. 16. Prise out and discard the oil seal at the front of the transfer box casing using service tool 1861271. 17. Drift out the input gear front bearing track. 8. Lift out the intermediate gear cluster and bearing 9. Remove the ‘0’ rings from the intermediate gear assembly . shaft and from inside the transfer box. $Ti x .J ST1576M - 92
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 ball with a suitable magnet. 22. Withdraw the centre differential and sclcctor shaft/ fork assembly. Rear output housing removal 23. Remove six bolts and washers and dctach the rear output housing and shaft assembly from the transfer casing. 24. Remove the gasket. Transfer case overhaul - dismantling 25. Remove the studs and dowels. 26. Remove the magnetic drain plug and fi!ler!level ST1581M 93
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 washer and tighten to the specified torque, loosely fit the filler/level plug. 29 Rear output housing overhaul -dismantling 1. Using - flange wrench 1861205 and socket spanner, remove the flange nut, steel and felt washers. Ensure flange bolts are fully engaged in the wrench. 2. Remove output flange with circlips attached. If necessary, use a two-legged puller. NOTE: The circlip need only be released if the flange bolts are to be renewed. 94 3. Remove speedo-drive housing. This can be prised out with a screwdriver. 4. Remove housing from the vice and drift out the output shaft, by striking the flange cnd of the shaft. 5. Carefully prise off thc oil catch ring using a screwdriver in the slot provided. 6. Prise out and discard the seal from the output 7. Using circlip pliers 18G2.57, rcmovc the circlip housing using tool 1SG1271. retaining the bearing.
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. Using a suitable press behind thc low range gear carefully remove the high/low hub and low range gcar. - ST1640M Centre differential unit overhaul -dismantling 1. Secure centre diffcrential unit to a vice fitted with soft jaws, and release stake nut from recess. 2. Remove stake nut using tool 1831423 and suitablc socket wrench. 3. Removc thc diffcrential unit from the vice. ST1593M 4. Secure hand press MS47 in vice with collars 18G47BB and using button 1847BB/3 rcmove the rear taper bearing and collars. ST1592M 8. Substituting collar LST47-1 remove front taper 9. Remove hand press from the vice. vice by gripping the hub splines. roller bearing. 10. Using soft jaws secure the differential unit in the STl596M \ll Y I 96
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