Land Rover Defender Workshop 1993 Rover Manual

LT230T TRANSFER GEARBOX 
DISMANTLE 
Transmission  brake removal  Intermediate 
shaft and gear  cluster  removal 
5. Release  stake nut from  recess  in intermediate 
shaft  and remove  stake nut and  discard. 
1. Remove two countersunk  screws and 6. Unscrew  the single  bolt and  remove  anti - 
withdraw  brake drum.  rotation 
plate at the  rear  face of the transfer 
2. Remove  four bolts  securing  the brake  back - box. 
plate;  the 
two bottom  fixings retain the oil 
catcher. 
NOTE: A  hexagonal...

9. Remove the O  rings  from the intermediate 
gear  shaft  and from  inside  the transfer  box 
and  discard. 
LT230T TRANSFER GEARBOX 
16. Remove  and discard  the oil seal  at the  front 
of  the  transfer  box casing  using service 
tool 
10. Remove  taper roller  bearings  and bearing  18G 1271 to prevent damage to the housing. 
spacer 
from the  intermediate  gear cluster 17. Drive out the  input  gear front  bearing  track. 
assembly. 
Input gear removal 
11. Remove  five bolts  and washers...

LT230T TRANSFER  GEARBOX 
22. Withdraw the centre  differential  and selector 
shaft/fork  assembly. 
High/low 
cross 
- shaft housing  removal  Centre 
differential  removal 
18. Remove the six bolts  and washers  retaining 21. Remove high/low selector shaft detent  plug, 
the  cross 
- shaft  housing  ground lead and  spring and retrieve  the ball  with a suitable 
retaining  clip.  magnet. 
19. Remove the cross - shaft  housing  and gasket 
discard  the gasket. 
Front  output  housing  removal 
20....

LT230T TRANSFER GEARBOX 
Transfer case overhaul - reassembling 
29. If previously  removed, fit studs and dowels to 
front  face of the transfer  casing. Use new 
components  where necessary. 
NOTE: The  position  of the  radial  dowel 
blade  is set  in  line  with the circle  which  is 
formed 
by the  front  output  housing fixing 
damage.  Remove if replacements  are holes. 
required. 
26. Remove the magnetic  drain plug, copper 30. Refit magnetic  drain plug with new copper 
washer  and filler/level...

LT230T TRANSFER GEARBOX 
Rear output  housing dismantle and  overhaul 4. Remove  housing from the  vice  and drive  out 
the  output
-shaft,  by striking  the  flange  end  of 
5. Carefully  lever off the oil catch  ring  using  a 
6. Remove and discard  the seal  from  the  output 
2. Remove  output  flange  with circlip  attached. If housing  using  tool 18G  1271 to avoid 
damaging the  housing. 
1. Using  flange  wrench 18G1205  and socket  the  shaft. 
wrench,  remove  the  flange  nut, steel and...

LT230T TRANSFER GEARBOX 
9. Remove  speedometer  gear (driven)  from its 
housing. 
10.  Remove  the O  ring  and oil seal  and discard. 
16. Carefully  coat the lips 
of the  seal  with clean 
grease  and refit oil catch  ring onto  output 
17.  Fit the  O  ring and oil seal  (lip side  inwards) 
to speedometer  housing. 
18.  Lubricate  the ‘O’ 
ring and  seal  with oil, 
19. Locate  speedometer  gear (driven)  in housing 
11. Slide off spacer  and speedometer  drive gear  housing. 
from  output...

LT230T TRANSFER GEARBOX 
20. Slide 
drive  gear and spacer  on to the output  4. Secure 
hand press  MS47  in vice  with  collars 
shaft.  18G47BB 
- 1 and using  button  18G47BB/3 
21.  Locate 
output shaft into the bearing  in the  remove the rear  taper  bearing  and collars. 
housing  and drive 
into position. 
22. Locate  speedometer  gear (driven)  housing 
assembly  into the output  housing  and press  in 
until  flush  with the housing  face. 
5. Remove  the high  range  gear and bush,  taking...

LT230T TRANSFER GEARBOX 
8. Substituting collar LST47 - 1 remove  front 
taper  roller bearing  from the differential. 
9. Remove  hand press  from the vice. 
10. Using  soft jaws  secure  the differential  unit in 
the  vice  by gripping  the hub  splines. 
16. Inspect  all components  for damage  or wear, fit 
new  components if necessary. 
17. Using soft jaws  secure  the rear  (longest  half) 
of the differential  unit in the vice  by gripping 
the  hub  splines. 
18. Lubricate  and install  the...

LT230T TRANSFER GEARBOX 
19. Lubricate and fit the front  bevel  gear and 
thinnest  thrust washer  (FRC6956  1.05mm). 
20.  Fit the  front  half of the  differential  casing 
ensuring  that the 
two engraved  arrows are 
aligned. 
21.  Fit securing  bolts and tighten 
to the correct 
torque  (see section  06 
- TORQUE VALUES). 
22. Lubricate  and insert  the rear  output  shaft into 
the  bevel  gear and check  that the gears  are 
free 
to rotate. 
NOTE:  Gears that have  been  run will rotate...

LT230T TRANSFER GEARBOX 
Re-assembling centre differential 
30. Fit the  selected  thrust washer  and bevel  gear 
into  the rear  differential  unit. 
38. Fit the  low  range  gear, with its dog  teeth 
uppermost 
to the  differential  assembly. 
39. Press the high/low  hub on to the differential 
splines. 
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...