Land Rover Defender Workshop 1993 Rover Manual

LT77S MANUAL GEARBOX 
Tool E. Workstand for securely  locating the gearbox 
during  overhaul.  Manufacture  from 30mm  x 30mm 
angle  iron. The single  hole marked  A should  be 
drilled  through  the material  with a 10mm  drill.  The 
four counter  sunk blind  holes  marked  B should 
also  be made  with a 10mm  drill, but must  not be 
drilled  through  the material. 
REISSUED: FEB 1993 45  

LT230T TRANSFER  GEARBOX 
REMOVE LT230T TRANSFER GEARBOX FROM 
THE LT77S GEARBOX 
Special Tool:  18G 1425-LRT-41-009 - Guide  studs 
(3)  also  locally  manufactured  adaptor  plate,  see 
below 
Adaptor  plate for removing  transfer gearbox 
The transfer  gearbox  should be removed  from 
underneath  the vehicle,  using a hydraulic  hoist. An 
adaptor  plate for locating  the transfer  gearbox  onto 
the  hoist  can be manufactured  locally 
to the drawing 
below. 
If a similar  adaptor  plate was made...

LT230T TRANSFER  GEARBOX 
22. Lower  the hoist  and withdraw  the transfer box 
Removing 
from  the vehicle, 
1. Install  the vehicle  on a ramp. 
2. Disconnect  the battery. 
3.  Remove  the cover  panel from the right
-hand 
seat  base. 
4. Remove  the breather  pipe union  from the 
transfer  gearbox  high/low  cross
-shaft housing. 
5. Disconnect  the high/low  lever. 
6. Disconnect  the transmission  brake cable at 
the  clevis  joint. 
7.  Raise  the vehicle  on the  ramp  and drain  the 
oil  from...

LT230T TRANSFER GEARBOX 
OVERHAUL 
Service Tools: 
18G47 - 7 Input  gear  cluster bearing  cones 
remover/replacer 
18G47BB 
-1  Adaptor  centre differential  bearing 
remover 
18G47BB 
- 3  Adaptor  centre  differential  bearing 
remover 
button 
18G1205  Drive flange wrench 
18G1271  Oil seal  remover  (optional) 
18G1422  Mainshaft rear  oil seal  replacer 
18G1423  Adaptor/socket  centre differential 
Locknut  remover/replacer 
18G1424  Centre differential bearing  replacer 
MS47  Hand press 
MS550...

LT230T TRANSFER GEARBOX 
TRANSFER GEARBOX DATA 
Front and rear  bevel  gear pre-load  ...................................  see text 
High  range  gear end-float  .................................................  0,05 to 0,15  mm (0.002  to 0.006  in) 
Front  differential  bearing pre-load  ....................................  0.56 to 1.69  Nm (5 to 15  in Ib) 
Input  gear bearing  pre-load  ..............................................  0.56 to 2.25  Nm (5 to 20  in Ib) 
Intermediate  shaft bearing...

LT230T TRANSFER GEARBOX 
TORQUE WRENCH  SETTING 
WARNING:  Components  in bold  type  must  not be re-used 
. 
COMPONENT  Nm ft Ib 
Pinch bolt - operating  arm to crank arm ................................. 7 to 10 5 to 7 
End  cover  gear change  housing 
............................................ 7 to 10 5 to 7 
Speedometer  cable retainer 
7 to 10 5 to 7 
Rear  output/speedometer  housing 
......................................... 
16 to 21 
Front  output  housing 
to transfer  case...

LT230T TRANSFER GEARBOX 
DIFFERENTIAL AND OUTPUT DRIVE ASSEMBLY 
1.  Differential  selector assembly 
2. Front output  housing 
3. 
4. 
5. 
6. High-low  selector  finger 
7. Differential lock selector shaft 
8.  Differential 
lock selector  fork 
9. 
10. 
11. 
12.  Front output  flange 
13.  Mud shield 
14.  Oil seal 
15.  Bearing 
16.  Spacer 
17.  Circlip 
18.  Differential carrier, 
front half 
19. Differential  carrier, rear half 
20.  Retaining  ring 
21.  Front 
output shaft 
22. 
23.  Selective...

LT230T TRANSFER  GEARBOX 
a REISSUED: FEB 1993  

LT230T TRANSFER GEARBOX 
REISSUED: FEB 1993