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 for the 
LT230R  transfer gearbox, 
it can be modified  to suit 
both  the LT230R  and LT230T  gearboxes 
by making 
the  modifications  shown by the  large  arrows. 
WARNING: Where  the  use of a transmission 
hoist  is necessary, 
it is absolutely  essential  to 
follow  the manufacturers  instructions  to ensure 
safe  and effective  use  of the  equipment. 
Material.  Steel plate BS 1449  Grade  4 or  14 
Holes  marked  thus * to  be  drilled  to fit  hoist  being 
used. 
REISSUED:  FEB 1993 1  
						

							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  the transfer  box. 
8. Remove  the centre  section  of the  exhaust 
system. 
9. Disconnect  the front  and rear  propeller  shafts 
from  the gearbox  and move  them aside. 
10.  Disconnect  the speedometer  cable from the 
transfer  gearbox. 
11. Remove  the split  pin at the  lower  end of the 
pivot  arm for the  differential  lock control. 
Then,  remove  the two  bolts  securing  the pivot 
arm to allow  the link to be disconnected.  Later 
models  disconnect  the connecting  link from 
the  differential  lock lever. 
12.  Manufacture  an adaptor  plate 
in accordance 
with  the drawing, 
to attach  to the  gearbox 
hoist  and transfer  box 
to facilitate  removal 
(RR244M). 
13. Place four, 30  mm  (1.250  in) long  spacers 
between  the top 
of the  hoist  and the adaptor 
plate  at the  securing  points and secure  the 
23. Make sure that the joint  faces  of the  transfer 
adaptor 
plate to the hoist. 
14. Remove  the four  central  bolts from the  box and  main  gearbox  extension  case are 
transfer  box bottom  cover, move the hoist  into  clean 
and that the three  guide  studs,  18G 
position  and secure  the adaptor  plate 
to the  1425, are fitted to the extension  case. 
transfer  box. 
24. Lubricate  the oil seal 
in the  joint  face  of 15. Adjust  the hoist  to take  the weight  of the 
transfer box, secure  the transfer  box to the 
transfer  box. 
adaptor plate on the  lifting  hoist and raise  the 
16. Remove  three nuts and bolts  securing  the  hoist until the transfer  box can  be located  over 
right
- hand  gearbox  mounting  bracket to the  the guide  studs. 
chassis,  then remove  the  nut from the rubber  25. Remove  the guide 
studs and  secure  the 
mounting  and withdraw  the bracket. 
transfer box 
to me main  gearbox  extension 
17.  Place  a suitable  wooden  block between  the  case. Tighten  the nuts  and 
bolts to the correct 
main  gearbox  and chassis  cross
-member,  torque. 
the  wooden  block. 
the removal  sequence,  noting the following 
18.  Disconnect  .the electrical  lead from  the  important points. 
differential  lock switch.  27. After  removing  the lifting  hoist and adaptor 
19. Move  the small  crank  lever, for the  high/low  plate from the transfer  box, clean  the threads 
selector,  upward 
to allow access to the  of the  four  bolts  for the  transfer  box bottom 
adjacent  nut securing  the transfer  box to the  cover, coat them  with Loctite 290, and fit them 
main  gearbox  extension  case. 
Later models  together with spring  washers.  Tighten 
to the 
remove  the lower  lock nut from  the high
-low  correct torque. 
operating  rod. 
28. Refill  the transfer  box 
with the correct  grade 20. Remove  the two nuts  and four  bolts  securing  oil to the oil level  plug hole. 
the  transfer  box 
to the main  gearbox  29. Check,  and if necessary  top up, the  oil level  in 
extension  case. 
the main  gearbox.  Use the correct  grade oil. 
21.  Fit three  guide  studs,  18G 1425,  through  the 
30. Check  the operation  of the  handbrake  and 
transfer  box bolt  holes 
to support it during  adjust as necessary. 
removal. 
Refitting 
then  lower  the hoist  until the gearbox  contacts 
26. Complete 
the refitting  procedure  by reversing 
2 
REISSUED: FEB 1993  
						

							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 
LST47 
- 1 Adaptor  centre differential  bearing 
LST104  Intermediate gear dummy  shaft 
LST105  Input gear mandrel 
LST550  - 4 Intermediate  gear bearing replacer 
NOTE:  Where the  use  of special  service  tools is 
specified,  only these  tools should  be used  to 
avoid  the  possibility  of personal  injury and or 
damage  to components. 
Bearing  and oil seal  replacer  handle 
remover  
						

							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  pre-load  .................................  0.56 to 1.69  Nm (5 to 15  Ib) 
4 REISSUED:  FEB 1993  
						

							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 .................................... 22 to 28 
16 to 21 
Cross  shaft housing 
to front output  housing .......................... 22 to 28 
16 to 21 
Gear  change  housing  22 to 28  16 
to 21 
Pivot shaft 
to link  arm ............................................................. 22 to 28 
16 to 21 
Connecting  rod 
to adjustable clevis ....................................... 22 to 28 
16 to 21 
Anti
-rotation  plate intermediate  shaft ..................................... 22 to 28 
16 to 21 
Front  output  housing  cover 
.................................................... 22 to 28 
16 to 21* 
Pivot  bracket 
to extension  housing ........................................ 22 to 28 
16 to 21* 
Finger  housing 
to front output  housing .................................. 22 to 28 
16 to 21 
Bearing  housing 
to transfer case ........................................... 22 to 28 16 to 21 
Brake  drum 
to coupling  flange ............................................... 22 to 28 
16 to 21 
Bearing  housing cover 
to transfer gearbox ............................ 40 to 50 29 to 37 
29 
to 37 
16 
to 21 
16 
to 21 
48 
to 59 
5 to 7 
4.82  max 
9 
to 37 
19 
to 26 
40 
to 47 
50 to 59 
19  to 26 
10 to 12 
30 
to 38 
30 
to 38 
24 
to 20 
38  13 
to 16 
................................................... 
See  note 
................................................ Bottom  cover to transfer  case 
22 to 28 
............................................................. 
Rear output  speedometer  housing to 
Selector finger to cross  shaft high/low  40 
to 50 
22 
to 28 
transfer 
gearbox 
.................................................................. 
................................... 
Selector  fork. high/low to shaft ............................................... 22 to 28 
Transmission  brake 
to speedometer housing ........................ 65 to 80 
Intermediate  shaft stake  nut ............................................... 
Gate plate to grommet  plate .................................................. 7 to 10 
Plunger switch setting ............................................................ 6.75 max 
Gearbox 
to transfer  case ....................................................... 40 to 50 
Gearbox to transfer case ....................................................... 
Oil drain plug ........................................................................\
.. 25 to 35 
Differential  case (front to rear) ............................................... 55 to 64 
Differential  case rear stake  nut ........................................... 66 to 80 
Oil filler/level  plug 
25 to 35 
Transfer breather ................................................................... 14 to 16 
Transfer  box front  drive  flange 
to drive shaft ......................... 41 to 52 
Transfer  box rear  drive  flange to drive  shaft .......................... 41 to 52 
Mounting  brackets to transfer  gearbox .................................. 52 
Mounting  rubbers 
to mounting brackets ................................. 20 to 22 
See text 
See  note 
........................................................................\
 Output  flanges  146 to 179 108 to 132 
................................................................... 
Transfer  gearbox mounting  brackets to chassis .................... 33 to 27 
NOTE:  Studs to be assembled  into casting  with sufficient  torque to wind  them  fully home,  but this 
torque  must not exceed  the maximum  figure quoted  for the  associated  nut on final  assembly 
. 
NOTE:  * These  bolts must have threads  coated with Loctite 290 prior to assembly . 
REISSUED: FEB 1993 5  
						

							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  shim 
24.  Bearing 
25. Selective  thrust washers 
26.  Sun and planet  gears 
27. Thrust  washers 
28. Cross shafts 
31. High output  gear 
32.  Bush 
33. Bearing 
34.  Bearing  retaining  nut 
35.  Differential 
lock switch 
36.  High
-low 
ratio  cross  shaft assembly 
High
-low  selector  shaft and lever 
High
-low  selector  fork and shaft 
Differential 
lock spring  and clips 
Front  output  housing  cover and housing 
Felt  washer,  steel washer  and flange  nut 
Dog  clutch,  front drive  lock
-up 
30.  Hub and sleeve  assembly 
Differential 
lock detent ball and  spring 
REISSUED: FEB 1993 7  
						

							LT230T TRANSFER  GEARBOX 
a REISSUED: FEB 1993  
						

							LT230T TRANSFER GEARBOX 
REISSUED: FEB 1993